Battery components comprising fibers

ABSTRACT

Battery components are generally provided. In some embodiments, the battery components can be used as pasting paper and/or capacitance layers for batteries, such as lead acid batteries. The battery components described herein may comprise a plurality of fibers. The battery component may include, in some embodiments, a plurality of fibers and, optionally, one or more additives such as conductive carbon and/or activated carbon. In certain embodiments, the plurality of fibers include relatively coarse glass fibers (e.g., having an average diameter of greater than or equal to 2 microns), relatively fine glass fibers (e.g., having an average diameter of less than 2 microns), and/or fibrillated fibers. In some instances, such fibers may be present in amounts such that the battery component has a particular surface area, mean pore size, and/or dry tensile strength.

FIELD OF INVENTION

The present embodiments relate generally to battery components, andspecifically, to battery components that can be used as pasting paperand/or capacitance layers for batteries, such as lead acid batteries.

BACKGROUND

Batteries convert stored chemical energy into electrical energy and arecommonly used as energy sources. Typically, a battery comprises one ormore electrochemical cells including a negative electrode, a positiveelectrode, an electrolyte, and one or more battery components. Forexample, a battery may comprise a battery component such as pastingpaper and/or a capacitance layer. Pasting paper is generally used tosupport wet lead paste during the manufacturing process ofelectrochemical cells in lead acid batteries including VRLA batteries.Capacitance layers generally provide a reservoir of electrons forbatteries which provides quick initial discharges and recharge pulses.

Such battery components should be chemically, mechanically, andelectrochemically stable under the strongly reactive environments in thebattery during operation, should not adversely interact with theelectrolyte and/or electrode materials, and have no deleterious effecton the battery's performance (e.g., energy production, cycle life,safety). For example, the battery component should not degrade, leachharmful components, react in a negative way with the electrodematerials, allow short circuits to form between the electrodes, and/orcrack or break during battery assembly and/or operation. Batteriescomponents also play a role in determining the assembly speed of thebattery, as well as the performance during service. For example, duringassembly, the properties of pasting paper may affect its processability.Though many battery components exist, improvements are needed.

SUMMARY

The present embodiments relate generally to battery components, andspecifically, to battery components that can be used as pasting paperand/or capacitance layers for batteries, such as lead acid batteries.

In one aspect, battery components are provided. In some embodiments, thebattery component comprises a plurality of fine glass fibers having anaverage fiber diameter of less than 2 microns, wherein the plurality offine glass fibers are present in an amount greater than or equal to 30wt % and less than or equal to 60 wt % versus the total weight of thebattery component. The battery component also comprises a plurality ofcoarse glass fibers having an average fiber diameter of greater than orequal to 2 microns, wherein the plurality of coarse glass fibers arepresent in an amount greater than or equal to 30 wt % and less than orequal to 60 wt % versus the total weight of the battery component. Thebattery component also comprises a plurality of fibrillated fiberspresent in an amount greater than or equal to 1 wt % and less than orequal to 15 wt % versus the total weight of the battery component. Thebattery component also comprises a resin present in an amount greaterthan or equal to 1 wt % and less than or equal to 10 wt % versus thetotal weight of the battery component. The battery component alsocomprises a plurality of bicomponent fibers present in an amount ofgreater than 0 wt % and less than or equal to 8 wt % versus the totalweight of the battery component.

In some embodiments, the battery component comprises a plurality of fineglass fibers having an average fiber diameter of less than 2 microns,wherein the plurality of fine glass fibers are present in an amountgreater than or equal to 30 wt % and less than or equal to 60 wt %versus the total weight of the battery component. The battery componentalso comprises a plurality of coarse glass fibers having an averagefiber diameter of greater than or equal to 2 microns, wherein theplurality of coarse glass fibers are present in an amount greater thanor equal to 30 wt % and less than or equal to 60 wt % versus the totalweight of the battery component. The battery component also comprises aplurality of fibrillated fibers present in an amount greater than orequal to 1 wt % and less than or equal to 15 wt % versus the totalweight of the battery component. The battery component also comprises aresin present in an amount greater than or equal to 1 wt % and less thanor equal to 10 wt % versus the total weight of the battery component.The battery component has an air permeability of greater than or equalto 1 CFM and less than or equal to 1000 CFM.

In some embodiments, the battery component comprises a plurality of fineglass fibers having an average fiber diameter of less than 2 microns,wherein the plurality of fine glass fibers are present in an amountgreater than or equal to 30 wt % and less than or equal to 60 wt %versus the total weight of the battery component. The battery componentalso comprises a plurality of coarse glass fibers having an averagefiber diameter of greater than or equal to 2 microns, wherein theplurality of coarse glass fibers are present in an amount greater thanor equal to 30 wt % and less than or equal to 60 wt % versus the totalweight of the battery component. The battery component also comprises aplurality of fibrillated fibers present in an amount greater than orequal to 1 wt % and less than or equal to 15 wt % versus the totalweight of the battery component. The battery component also comprises aresin present in an amount greater than or equal to 1 wt % and less thanor equal to 10 wt % versus the total weight of the battery component,wherein the resin is hydrophobic.

In some embodiments, the battery component comprises a plurality of fineglass fibers having an average fiber diameter of less than 2 microns, aplurality of coarse glass fibers having an average fiber diameter ofgreater than or equal to 2 microns, and a plurality of fibrillatedfibers. The battery component has a surface area of greater than orequal to 0.5 m²/g and less than or equal to 100 m²/g. The batterycomponent has a mean pore size of greater than or equal to 0.1 micronsand less than or equal to 15 microns. The battery component has a drytensile strength in the machine direction of greater than or equal to0.1 lbs. per inch and less than or equal to 15 lbs. per inch.

In some embodiments, the battery component comprises a layer comprisinga plurality of glass fibers, conductive carbon, activated carbon, abinder, and a hydrogen suppressant. The conductive carbon and theactivated carbon form a total carbon, and the total carbon in thebattery component is present in an amount of greater than or equal to 80wt % and less than or equal to 90 wt % versus the total weight of thebattery component. The plurality of glass fibers are present within thebattery component in an amount of greater than 0 wt % and less than orequal to 95 wt % versus the total weight of the battery component. Thebinder is present in the battery component in an amount of less than orequal to 5 wt % and greater than or equal to 1 wt % versus the totalweight of the battery component. The hydrogen suppressant is present inthe battery component in an amount greater than or equal to 0.1 wt % andless than or equal to 10 wt % versus the total weight of the batterycomponent. The ratio of activated carbon to conductive carbon is greaterthan or equal to 70:30 and less than or equal to 99:1.

In another aspect, battery plates are provided. In some embodiments, thebattery plate comprises a lead grid and a battery component, such as onedescribed above or herein.

In yet another aspect, lead acid batteries are provided. In someembodiments, the lead acid battery comprises a negative plate, apositive plate, and a battery component (such as one described above orherein) disposed between the negative and positive plates.

In some embodiments, the battery component described above and/or hereincomprises activated carbon. In some embodiments, the battery componentcomprises conductive carbon. In some embodiments, the ratio of activatedcarbon to conductive carbon is greater than or equal to 90:10 and lessthan or equal to 94:6. In some embodiments, the activated carbon and/orconductive carbon is deposited on the battery component. In someembodiments, the activated carbon and/or conductive carbon is presentwithin the battery component.

In some embodiments, the battery component described above and/or hereincomprises a hydrogen suppressant in an amount of less than or equal to 2wt % versus the total weight of the battery component. In someembodiments, the hydrogen suppressant is selected from the groupconsisting of oxides, hydroxides, sulfates, tin, titanium, cobalt,antimony, and combinations thereof.

In some embodiments, the total weight of fine glass fibers and coarseglass fibers is less than or equal to 98 wt % versus the total weight ofthe battery component described above and/or herein. In someembodiments, the plurality of fine glass fibers have an average fiberdiameter of less than or equal to 1 micron. In some embodiments, theplurality of coarse glass fibers have an average fiber diameter ofgreater than 5 microns. In some embodiments, the plurality offibrillated fibers have an average length of less than or equal to 25mm. In some embodiments, the plurality of fibrillated fibers have aCanadian Standard Freeness (CSF) of greater than or equal to 20 CSF andless than or equal to 650 CSF. In some embodiments, the plurality offibrillated fibers comprise cellulose-based fibers, acrylics, liquidcrystalline polymers, polyoxazoles, aramids, p-aramids, polyethylenes,polyesters, polyamides, cotton, polyolefins, and/or olefins.

In some embodiments, the resin in the battery component described aboveand/or herein is a hydrophobic resin. In some embodiments, the resin hasa contact angle of greater than 90 degrees, according to standard ASTMD5946 (2009).

In some embodiments, the battery component described above and/or hereinhas a Cobb parameter of greater than or equal to 50 gsm.

In some embodiments, the battery component described above and/or hereinhas a basis weight of greater than or equal to 10 g/m² and less than orequal to 200 g/m². In some embodiments, the battery component describedabove and/or herein has an average thickness of greater than or equal to0.1 mm and less than or equal to 0.6 mm. In some embodiments, thebattery component described above and/or herein has a specific surfacearea of greater than or equal to 0.2 m²/g and less than or equal to 5m²/g. In some embodiments, the battery component described above and/orherein has a maximum pore size greater than or equal to 5 microns andless than or equal to 100 microns. In some embodiments, the batterycomponent described above and/or herein has a mean pore size of greaterthan or equal to 0.1 microns and less than or equal to 15 microns.

In some embodiments, the battery component described above and/or hereinhas a dry tensile strength of greater than or equal to 0.1 pounds perinch and less than or equal to 15 pounds per inch.

In some embodiments, the ratio of activated carbon to conductive carbonin the battery component described above and/or herein is greater thanor equal to 90:10 and less than or equal to 94:6.

In some embodiments, the plurality of glass fibers are present withinthe battery component described above and/or herein in an amount ofgreater than or equal to 85 wt % and less than or equal to 95 wt %. insome embodiments, the plurality of glass fibers are present within thebattery component described above and/or herein in an amount of greaterthan or equal to 5 wt % and less than or equal to 50 wt %.

In some embodiments, the binder in the battery component described aboveand/or herein is selected from the group consisting of PTFE, CMC, SBR,acrylic, PVDF, and combinations thereof.

Other advantages and novel features of the present invention will becomeapparent from the following detailed description of various non-limitingembodiments of the invention when considered in conjunction with theaccompanying figures. In cases where the present specification and adocument incorporated by reference include conflicting and/orinconsistent disclosure, the present specification shall control. If twoor more documents incorporated by reference include conflicting and/orinconsistent disclosure with respect to each other, then the documenthaving the later effective date shall control.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting embodiments of the present invention will be described byway of example with reference to the accompanying figure, which isschematic and is not intended to be drawn to scale. In the figure, eachidentical or nearly identical component illustrated is typicallyrepresented by a single numeral. For purposes of clarity, not everycomponent is labeled, nor is every component of each embodiment of theinvention shown where illustration is not necessary to allow those ofordinary skill in the art to understand the invention. In the figures:

FIG. 1 is a schematic diagram of a battery component including a fiberlayer according to one set of embodiments;

FIG. 2 is a schematic diagram showing a cross section of a fiber layerincluding a plurality of fibers and an additive according to one set ofembodiments; and

FIG. 3 is a plot illustrating the relationship between dry tensilestrength, mean pore size, and specific surface area for a batterycomponent according to some embodiments.

DETAILED DESCRIPTION

Battery components are generally provided. In some embodiments, thebattery components can be used as pasting paper and/or capacitancelayers for batteries, such as lead acid batteries. The batterycomponents described herein may comprise a plurality of fibers. Thebattery component may include, in some embodiments, a plurality offibers and, optionally, one or more additives such as conductive carbonand/or activated carbon. In some embodiments, the plurality of fibersinclude relatively coarse glass fibers (e.g., having an average diameterof greater than or equal to 2 microns), relatively fine glass fibers(e.g., having an average diameter of less than 2 microns), and/orfibrillated fibers. In some instances, such fibers may be present inamounts such that the battery component has a particular surface area,mean pore size, and/or dry tensile strength.

In some cases, the battery component may be useful as a pasting paper inan electrochemical cell. Advantageously, the combination of glass fibersand fibrillated fibers within a battery component having featuresdescribed herein (e.g., a pasting paper) may exhibit a balance betweenresistance to acid stratification, ease of processability (e.g.,mechanical manipulation), and increased paste adhesion. By contrast,pasting paper including all glass fibers may exhibit poor adhesion to anelectroactive material and/or may be susceptible to damage (e.g.,tearing, puncturing) during processing. Pasting paper comprisingprimarily cellulose-based fibers may exhibit poor resistance to acidstratification and/or leaching of undesirable organic contaminants intoan electrolyte in the electrochemical cell, since cellulose may dissolvein the electrolyte. Moreover, dissolution of components of the pastingpaper in the electrolyte frees up space previously occupied by thepaper, resulting in decreased pressure inside the battery, and can leadto reduced cycle life of the battery.

In some embodiments, a battery component described herein may beconductive. For example, in some embodiments, the battery componentcomprises one or more additives such as activated carbon and/orconductive carbon. In some embodiments, the conductive battery componentmay be useful as a conductive layer or capacitance layer within anelectrochemical cell (e.g., a layer capable of storing non-faradiccharge in or on the layer). Without wishing to be bound by theory, suchconductive battery components may provide a readily available source ofelectrons within a battery. The battery component may advantageouslyresult in a reduction of delay of initial discharge of the battery,replenish freshly discharged active material, improve charge acceptance,and/or lead to an increase in the lifetime of the battery.

In some embodiments, such improvements may be achieved while havingrelatively minimal or no adverse effects on another property of thebattery component and/or the overall battery. The battery componentsdescribed herein may be well suited for a variety of battery types,including lead acid batteries.

A non-limiting example of a battery component including a plurality offibers is shown schematically in FIG. 1. A battery component 5 mayinclude a fiber layer 6 comprising a plurality of fibers. In someembodiments, the fiber layer includes a plurality of glass fibers (e.g.,a plurality of coarse glass fibers, a plurality of fine glass fibers)and/or a plurality of fibrillated fibers. The fiber layer may alsoinclude a plurality of synthetic fibers, such as monocomponent and/orbicomponent fibers, and/or a resin. In some embodiments, the batterycomponent may be a single layer (e.g., the component does not includelayer 7 in FIG. 1). For instance, the battery component may be formed ofa single fiber layer.

In other embodiments, the battery component may comprise multiplelayers. For instance, in addition to fiber layer 6, the batteryseparator may include an optional layer 7 (e.g., additional layer),which may be adjacent the fiber layer (e.g., contacting one or moresides of the fiber layer). In some embodiments, the multi-layer batterycomponent may include at least one fiber layer (e.g., at least two fiberlayers, at least three fiber layers), with at least one fiber layerincluding a plurality of glass fibers and a plurality of fibrillatedfibers, as described herein.

As used herein, when a layer is referred to as being “adjacent” anotherlayer, it can be directly adjacent to the layer, or an intervening layeralso may be present. A layer that is “directly adjacent” another layermeans that no intervening layer is present.

In some embodiments, one or more optional layers (e.g., additionallayers) may be present in the battery component. Non-limiting examplesof optional/additional layers include fiber layers such as thosecomprising a plurality of glass fibers, which optionally includeactivated carbon particles and conductive carbon particles. In someembodiments, however, the one or more optional layers may besubstantially free of activated carbon and conductive carbon particles.Other types of layers are also possible. For example, in some cases, theone or more optional layers may include a battery grid (e.g., a leadgrid).

It should be understood that the configurations of the layers shown inthe figures are by way of example only, and that in other embodiments,battery components including other configurations of layers may bepossible. Furthermore, in some embodiments, additional layers may bepresent in addition to the ones shown in the figures. It should also beappreciated that not all components shown in the figures need be presentin some embodiments.

In some embodiments, the battery component comprises a fiber layer thatis positioned adjacent (e.g., directly adjacent) a battery grid (e.g., alead grid). In some embodiments, formation of a portion of the batterymay involve positioning (e.g., via a conveyer belt) a fiber layeradjacent a battery grid and adding a paste (e.g., a paste mixturecomprising one or more of electroactive material, lead oxide, pure lead,carbon, sulfuric acid, sodium lignosulfonate, graphite, expandedgraphite, carbon black, barium sulfate, lead sulfate, and/or a pluralityof fibers such as glass fibers, PET fibers, and/or cellulose fibers)such that the fiber layer adheres to the battery grid. In someembodiments, the battery component comprises a first fiber layer and asecond fiber layer. The first fiber layer may be adjacent a firstsurface of the battery grid and the second fiber layer may be adjacent asecond surface of the battery grid.

Advantageously, the fiber layer(s) described herein may have asufficient tensile strength and may comprises a combination of fiberssuch that the fiber layer is not damaged during the formation and/or useof the battery component (e.g., during charge/discharge of theelectrochemical cell comprising the battery component). The fiberlayer(s) may be designed to be retained within the battery throughoutthe lifetime of the battery. In some embodiments, the mean pore size ofthe fiber layer is tailored such that the fiber layer has good adhesionto the battery grid (e.g., via embedding in active material paste) afterprocessing. The fiber layer(s) may be designed to have a balance ofproperties including tensile strength, mean pore size, and specificsurface area such that a battery component comprising the fiber layerhas desirable adhesive properties, mechanical robustness, and desirableresistance to acid stratification.

In some embodiments, a fiber layer includes a plurality of glass fibers(e.g., fine glass fibers, coarse glass fibers). In some embodiments, thefiber layer may also comprise a plurality of fibrillated fibers,although fibrillated fibers need not be present in some embodiments.Accordingly, in some embodiments fibrillated fibers are absent from abattery component described herein.

As described herein, the battery component may include a plurality offine glass fibers. The plurality of fine glass fibers in the batterycomponent generally have an average fiber diameter of less than 2microns. For example, in some embodiments, the plurality of fine glassfibers have an average fiber diameter of less than 2 microns, less thanor equal to 1.75 microns, less than or equal to 1.5 microns, less thanor equal to 1.25 microns, less than or equal to 1 microns, less than orequal to 0.5 microns, or less than or equal to 0.2 microns. In someembodiments, the plurality of fine glass fibers have an average fiberdiameter of greater than or equal to 0.1 microns, greater than or equalto 0.2 microns, greater than or equal to 0.5 microns, greater than orequal to 1 micron, or greater than or equal to 1.5 microns. Combinationsof the above-referenced ranges are possible (e.g., less than 2 micronsand greater than or equal to 0.1 microns, less than or equal to 1.5microns and greater than or equal to 0.5 microns). Other ranges are alsopossible. In some embodiments, the plurality of fine glass fibers are aplurality of microglass fibers. Other types of fibers having an averagefiber diameter of less than or 2 microns are also possible.

In some embodiments, the plurality of fine glass fibers are present inthe battery component (or in a fiber layer of the battery component) inan amount greater than or equal to 30 wt %, greater than or equal to 35wt %, greater than or equal to 40 wt %, greater than or equal to 45 wt%, greater than or equal to 50 wt %, or greater than or equal to 55 wt %versus the total weight of the battery component (or a fiber layer ofthe battery component). In some embodiments, the plurality of fine glassfibers are present in the battery component (or in a fiber layer of thebattery component) in an amount less than or equal to 60 wt %, less thanor equal to 55 wt %, less than or equal to 50 wt %, less than or equalto 45 wt %, or less than or equal to 35 wt % versus the total weight ofthe battery component (or a fiber layer of the battery component).Combinations of the above referenced ranges are possible (e.g., greaterthan or equal to 30 wt % and less than or equal to 60 wt %, greater thanor equal to 35 wt % and less than or equal to 55 wt %, greater than orequal to 40 wt % and less than or equal to 50 wt %). Other ranges arealso possible.

As described herein, the battery component (or a fiber layer of thebattery component) may include a plurality of coarse glass fibers. Theplurality of coarse glass fibers generally have an average fiberdiameter of greater than or equal to 2 microns. For example, in certainembodiments, the plurality of coarse glass fibers have an average fiberdiameter of greater than or equal to 2 microns, greater than or equal to5 microns, greater than or equal to 7 microns, greater than or equal to10 microns, greater than or equal to 12 microns, greater than or equalto 15 microns, greater than or equal to 17 microns, greater than orequal to 20 microns, greater than or equal to 25 microns, greater thanor equal to 30 microns, greater than or equal to 35 microns, or greaterthan or equal to 40 microns. In some embodiments, the plurality ofcoarse glass fibers have an average fiber diameter of less than or equalto 50 microns, less than or equal to 40 microns, less than or equal to30 microns, less than or equal to 20 microns, less than or equal to 15microns, less than or equal to 10 microns, or less than or equal to 5microns. Combinations of the above referenced ranges are possible (e.g.,greater than or equal to 2 microns and less than or equal to 50 microns,greater than or equal to 2 microns and less than or equal to 15microns). Other ranges are also possible. In some embodiments, theplurality of coarse glass fibers may comprise, or are, a plurality ofchopped strand fibers, which are described in more detail below.

In some embodiments, the plurality of coarse glass fibers are present inthe battery component (or in a fiber layer of the battery component) inan amount greater than or equal to 30 wt %, greater than or equal to 35wt %, greater than or equal to 40 wt %, greater than or equal to 45 wt%, greater than or equal to 50 wt %, or greater than or equal to 55 wt %versus the total weight of the battery component (or a fiber layer ofthe battery component). In certain embodiments, the plurality of coarseglass fibers are present in the battery component (or in a fiber layerof the battery component) in an amount less than or equal to 60 wt %,less than or equal to 55 wt %, less than or equal to 50 wt %, less thanor equal to 45 wt %, or less than or equal to 35 wt % versus the totalweight of the battery component (or a fiber layer of the batterycomponent). Combinations of the above referenced ranges are possible(e.g., greater than or equal to 30 wt % and less than or equal to 60 wt%, greater than or equal to 35 wt % and less than or equal to 55 wt %,greater than or equal to 40 wt % and less than or equal to 50 wt %)versus the total weight of the battery component (or a fiber layer ofthe battery component). Other ranges are also possible.

In some embodiments, the total weight of all glass fibers (e.g.,comprising coarse and fine glass fibers) present in the batterycomponent (or in a fiber layer of the battery component) is greater thanor equal to 60 wt %, greater than or equal to 65 wt %, greater than orequal to 70 wt %, greater than or equal to 75 wt %, greater than orequal to 80 wt %, greater than or equal to 85 wt %, greater than orequal to 90 wt %, or greater than or equal to 95 wt % versus the totalweight of the battery component (or a fiber layer of the batterycomponent). In certain embodiments, the total weight of all glass fiberspresent in the battery component is less than or equal to 98 wt %, lessthan or equal to 95 wt %, less than or equal to 90 wt %, less than orequal to 85 wt %, less than or equal to 80 wt %, less than or equal to75 wt %, or less than or equal to 70 wt % versus the total weight of thebattery component (or a fiber layer of the battery component).Combinations of the above-referenced ranges are possible (e.g., greaterthan or equal to 60 wt % and less than or equal to 98 wt %, greater thanor equal to 65 wt % and less than or equal to 95 wt %, greater than orequal to 70 wt % and less than or equal to 95 wt %). Other ranges arealso possible.

In some embodiments, the plurality of fine glass fibers may have aparticular average length. In some embodiments, the average length ofthe plurality of fine glass fibers is greater than or equal to 0.001 mm,greater than or equal to 0.01 mm, greater than or equal to 0.05 mm,greater than or equal to 0.1 mm, greater han or equal to 0.5 mm, greaterthan or equal to 1 mm, greater than or equal to 2 mm, or greater than orequal to 5 mm. In certain embodiments, the average length of theplurality of fine glass fibers is less than or equal to 10 mm, less thanor equal to 5 mm, less than or equal to 2 mm, less than or equal to 1mm, less than or equal to 0.5 mm, less than or equal to 0.1 mm, lessthan or equal to 0.05 mm, or less than or equal to 0.01 mm. Combinationsof the above-referenced ranges are possible (e.g., greater than or equalto 0.001 mm and less than or equal to 10 mm, greater than or equal to0.01 mm and less than or equal to 5 mm). Other ranges are also possible.

In some embodiments, the plurality of coarse glass fibers may have aparticular average length. In some embodiments, the average length ofthe plurality of coarse glass fibers is greater than or equal to 0.01mm, greater than or equal to 0.05 mm, greater than or equal to 0.1 mm,greater than or equal to 0.5 mm, greater than or equal to 1 min, greaterthan or equal to 2 mm, greater than or equal to 5 mm, greater than orequal to 10 mm, greater than or equal to 15 mm, or greater than or equalto 20 mm. In certain embodiments, the average length of the plurality ofcoarse glass fibers is less than or equal to 25 mm, less than or equalto 20 mm, less than or equal to 15 mm, less than or equal to 10 mm, lessthan or equal to 5 mm, less than or equal to 2 mm, less than or equal to1 mm, or less than or equal to 0.5 mm. Combinations of theabove-referenced ranges are possible (e.g., greater than or equal to0.01 mm and less than or equal to 25 mm, greater than or equal to 0.1 mmand less than or equal to 15 mm). Other ranges are also possible.

In certain embodiments, the battery component (or a fiber layer of thebattery component) may include microglass fibers, chopped strand glassfibers, or a combination thereof. Microglass fibers and chopped strandglass fibers are known to those skilled in the art. One skilled in theart is able to determine whether a glass fiber is microglass or choppedstrand by observation (e.g., optical microscopy, electron microscopy).Microglass fibers may also have chemical differences from chopped strandglass fibers. In some cases, though not required, chopped strand glassfibers may contain a greater content of calcium or sodium thanmicroglass fibers. For example, chopped strand glass fibers may be closeto alkali free with high calcium oxide and alumina content. Microglassfibers may contain 10-15% alkali (e.g., sodium, magnesium oxides) andhave relatively lower melting and processing temperatures. The termsrefer to the technique(s used to manufacture the glass fibers. Suchtechniques impart the glass fibers with certain characteristics. Ingeneral, chopped strand glass fibers are drawn from bushing tips and cutinto fibers in a process similar to textile production. Chopped strandglass fibers are produced in a more controlled manner than microglassfibers, and as a result, chopped strand glass fibers will generally haveless variation in fiber diameter and length than microglass fibers.Microglass fibers are drawn from bushing tips and further subjected toflame blowing or rotary spinning processes. In some cases, finemicroglass fibers may be made using a remelting process. In thisrespect, microglass fibers may be fine or coarse. As used herein, finemicroglass fibers are less than 2 micron in diameter and coarsemicroglass fibers are greater than or equal to 2 microns in diameter.

The microglass fibers of the battery component (or a fiber layer of thebattery component) may can have small diameters such as less than 10.0microns. For example, the average diameter of the microglass fibers in abattery component or layer may be less than or equal to 9.0 microns,less than or equal to 7.0 microns, less than or equal to 5.0 microns,less than or equal to 3.0 microns, or less than or equal to 1.0 microns.The average diameter of the microglass fibers in a battery component orlayer may be at least 0.1 microns, at least 0.3 microns, at least 0.5microns, at least 1 micron, at least 3 microns, at least 5 microns, orat least 7 microns. Combinations of the above-referenced ranges are alsopossible (e.g., at least 0.1 microns and less than or equal to 9.0microns, at least 1 micron and less than or equal to 5.0 microns). Othervalues are also possible. Average diameter distributions for microglassfibers are generally log-normal. However, it can be appreciated thatmicroglass fibers may be provided in any other appropriate averagediameter distribution (e.g., Gaussian distribution).

The microglass fibers may vary significantly in length as a result ofprocess variations. The aspect ratios (length to diameter ratio) of themicroglass fibers in a layer may be generally in the range of about 100to 10,000. In some embodiments, the aspect ratio of the microglassfibers in a layer are in the range of about 200 to 2500; or, in therange of about 300 to 600. In some embodiments, the average aspect ratioof the microglass fibers in a layer may be about 1,000, or about 300. Itshould be appreciated that the above-noted dimensions are not limitingand that the microglass fibers may also have other dimensions.

Non-limiting examples of microglass fibers are M-glass fibers accordingto Man Made Vitreous Fibers by Nomenclature Committee of TIMA Inc. March1993, Page 45.

Coarse microglass fibers may be included within a battery component (ora fiber layer of the battery component) in any suitable amount withrespect to the total weight of the glass fibers. In some embodiments,coarse microglass fibers are present in an amount greater than or equalto 20 wt %, greater than or equal to 30 wt %, greater than or equal to40 wt %, greater than or equal to 50 wt %, greater than or equal to 60wt %, greater than or equal to 70 wt %, or greater than or equal to 80wt % with respect to the total weight of the glass fibers. In certainembodiments, the coarse microglass fibers are present in an amount lessthan or equal to 90 wt %, less than or equal to 80 wt %, less than orequal to 70 wt %, less than or equal to 60 wt %, less than or equal to50 wt %, less than or equal to 40 wt %, or less than or equal to 30 wt %with respect to the total weight of the glass fibers. Combinations ofthe above referenced ranges are possible (e.g., greater than or equal to30 wt % and less than or equal to 60 wt %). Other ranges are alsopossible.

Fine microglass fibers may be included within a battery component (or afiber layer of the battery component) in any suitable amount withrespect to the total weight of the glass fibers. In some embodiments,fine microglass fibers are present in an amount of 0%, greater than orequal to 5 wt %, greater than or equal to 10 wt %, greater than or equalto 20 wt %, greater than or equal to 30 wt %, greater than or equal to40 wt %, greater than or equal to 50 wt %, or greater than or equal to60 wt % with respect to the total weight of the glass fibers. In certainembodiments, the fine microglass fibers are present in an amount lessthan or equal to 70 wt %, less than or equal to 60 wt %, less than orequal to 50 wt %, less than or equal to 40 wt %, less than or equal to30 wt %, less than or equal to 20 wt % or less than or equal to 10 wt %with respect to the total weight of the glass fibers. Combinations ofthe above referenced ranges are possible (e.g., greater than or equal to30 wt % and less than or equal to 60 wt %). Other ranges are alsopossible.

The chopped strand glass fibers may have an average fiber diameter thatis greater than the diameter of the microglass fibers. In someembodiments, the chopped strand glass fibers have a diameter of at least5.0 microns, e.g., up to 30.0 microns. For instance, the chopped strandglass fibers may have a diameter of at least 6.0 microns, at least 8.0microns, at least 10.0 microns, at least 15.0 microns, at least 20.0microns, or at least 25.0 microns, In some embodiments, the choppedstrand glass fibers may have a fiber diameter of less than or equal to30.0 microns, less than or equal to 25.0 microns, less than or equal to20.0 microns. less than or equal to 15.0 microns, less than or equal to12.0 microns, less than or equal to 10.0 microns, less than or equal to8.0 microns, or less than or equal to 6.0 microns. Combinations of theabove-referenced ranges are also possible (e.g., at least 5 microns andless than or equal to 12 microns). Other values are also possible.Average diameter distributions for chopped strand glass fibers aregenerally log-normal. Chopped strand diameters tend to follow a normaldistribution. Though, it can be appreciated that chopped strand glassfibers may be provided in any appropriate average diameter distribution(e.g., Gaussian distribution).

In some embodiments, the average length of the chopped strand glassfibers may be less than or equal to 25 mm, less than or equal to 10 mm,less than or equal to 8 mm, less than or equal to 6 mm, less than orequal to 5 mm, or less than or equal to 4 mm. In certain embodiments,the average length of the chopped strand glass fibers may be greaterthan or equal to greater than or equal to 3 mm, greater than or equal to4 mm, greater than or equal to 5 mm, greater than equal to 6 mm, greaterthan or equal to 8 mm, or greater than or equal to 10 mm. Combinationsof the above referenced ranges are also possible (e.g., an averagelength of greater than or equal to 3 mm and less than or equal to 25 mm,greater than or equal to 3 mm and less or equal to than 10 mm). Otherranges are also possible.

It should be appreciated that the above-noted dimensions are notlimiting and that the microglass and/or chopped strand fibers may alsohave other dimensions.

Chopped strand glass fibers may be included within a battery component(or a fiber layer of the battery component) in any suitable amounts withrespect to the total weight of the glass fibers. In some embodiments,chopped strand glass fibers are present in an amount of 0%, greater thanor equal to 10 wt %, greater than or equal to 20 wt %, greater than orequal to 30 wt %, greater than or equal to 40 wt %, greater than orequal to 50 wt %, greater than or equal to 60 wt %, greater than orequal to 70 wt %, or greater than or equal to 80 wt % with respect tothe total weight of the glass fibers. In certain embodiments, thechopped strand glass fibers are present in an amount less than or equalto 90 wt %, less than or equal to 80 wt %, less than or equal to 70 wt%, less than or equal to 60 wt %, less than or equal to 50 wt %, lessthan or equal to 40 wt %, less than or equal to 30 wt %, less than orequal to 20 wt %, or less than or equal to 10 wt % with respect to thetotal weight of the glass fibers. Combinations of the above referencedranges are possible (e.g., greater than or equal to 30 wt % and lessthan or equal to 60 wt %). Other ranges are also possible.

As described herein, in some embodiments, the battery component maycomprise a plurality of fibrillated fibers. As known to those ofordinary skill in the art, a fibrillated fiber includes a parent fiberthat branches into smaller diameter fibrils, which can, in someinstances, branch further out into even smaller diameter fibrils withfurther branching also being possible. The branched nature of thefibrils leads to a layer and/or fiber web having a high surface area andcan increase the number of contact points between the fibrillated fibersand other fibers in the layer. Such an increase in points of contactbetween the fibrillated fibers and other fibers and/or components of thelayer may contribute to enhancing mechanical properties (e.g.,flexibility, strength.) of the battery component. Non-limiting examplesof suitable materials for fibrillated fibers include cellulose-basedfibers (e.g. cellulose wood such as cedar, cellulose non-wood),regenerated cellulose (e.g., synthetic cellulose such lyocell, rayon),acrylics, liquid crystalline polymers, polyoxazoles (e.g.,poly(p-phenylene-2,6-benzobisoxazole), aramids, p-aramids,polyethylenes, polyesters, polyamides, cotton, polyolefins, and olefins.

In some embodiments, the plurality of fibrillated fibers are present inthe battery component (or in a fiber layer of the battery component) inan amount greater than or equal to 1 wt %, greater than or equal to 2.5wt %, greater than or equal to 5 wt %, greater than or equal to 7.5 wt%, greater than or equal to 10 wt %, or greater than or equal to 12.5 wt% versus the total weight of th.e battery component (or a fiber layer ofthe battery component). In certain embodiments, the plurality offibrillated fibers are present in the battery component in an amount ofless than or equal to 15 wt %, less than or equal to 12.5 wt %, lessthan or equal to 10 wt %, less than or equal to 7.5 wt %, less than orequal to 5 wt %, or less than or equal to 2.5 wt % versus the totalweight of the battery component (or a fiber layer of the batterycomponent). Combinations of the above referenced ranges are possible(e.g., greater than or equal to 1 wt % and less than or equal to 15 wt%, greater than or equal to 1 wt % and less than or equal to 10 wt %,greater than or equal to 1 wt % and less than or equal to 7.5 wt %).Other ranges are also possible.

In certain embodiments, the plurality of fibrillated fibers may becharacterized by a level of fibrillation as determined by the CanadianStandard Freeness (CSF) test, specified by TAPPI test method T 227 om 09Freeness of pulp. The test can provide an average CSF value. In someembodiments, the level of fibrillation of the plurality of fibrillatedfibers may be greater than or equal to 20 CSF, greater than or equal to50 CSF, greater than or equal to 75 CSF, greater than or equal to 100CSF, greater than or equal to 200 CSF, greater than or equal to 400 CSF,or greater than or equal to 600 CSF. In certain embodiments, the levelof fibrillation of the plurality of fibrillated fibers may be less thanor equal to 650 CSF, less than or equal to 600 CSF, less than or equalto 400 CSF, less than or equal to 200 CSF, less than or equal to 100CSF, less than or equal to 75 CSF, or less than or equal to 50 CSF.Combinations of the above-referenced ranges are possible (e.g., greaterthan or equal to 20 CSF and less than or equal to 650 CSF, greater thanor equal to 20 CSF and less than or equal to 100 CSF). Other ranges arealso possible.

In certain embodiments, the parent fibers of the plurality offibrillated fibers may have a particular average fiber diameter. Forexample, in certain embodiments, the parent fibers of the plurality offibrillated fibers have an average fiber diameter of greater than orequal to 0.1 microns, greater than or equal to 0.5 microns, greater thanor equal to 1 micron, greater than or equal to 2 microns, greater thanor equal to 5 microns, greater than or equal to 10 microns, greater thanor equal to 15 microns, greater than or equal to 20 microns, greaterthan or equal to 30 microns, or greater than or equal to 40 microns. Insome embodiments, the plurality of fibrillated fibers have an averagefiber diameter of less than or equal to 50 microns, less than or equalto 40 microns, less than or equal to 30 microns, less than or equal to20 microns, less than or equal to 15 microns, less than or equal to 10microns, less than or equal to 5 microns, less than or equal to 2microns, less than or equal to 1 micron, or less than or equal to 0.5microns. Combinations of the above referenced ranges are possible (e.g.,greater than or equal to 1 microns and less than or equal to 50 microns,greater than or equal to 0.1 microns and less than or equal to 30microns). Other ranges are also possible.

The average fiber diameter of the fibrils of the fibrillated fibers isgenerally less than the average fiber diameter of the parent fibers.Depending on the average fiber diameter of the parent fibers, in someembodiments, the fibrils may have an average fiber diameter of less thanor equal to 25 microns, less than or equal to 20 microns, less than orequal to 10 microns, less than or equal to 5 microns, less than or equalto 1 micron, less than or equal to 0.5 microns, less than or equal to0.1 microns, less than or equal to 0.05 microns, or less than or equalto 0.01 microns. In some embodiments the fibrils may have an averagefiber diameter of greater than or equal to 0.003 microns, greater thanor equal to 0.01 micron, greater than or equal to 0.05 microns, greaterthan or equal to 0.1 microns, greater than or equal to 0.5 micronsgreater than or equal to 1 micron, greater than or equal to 5 microns,greater than or equal to 10 microns, or greater than or equal to 20microns. Combinations of the above referenced ranges are also possible(e.g., fibrils having an average fiber diameter of greater than or equalto 0.01 microns and less than or equal to 20 microns). Other ranges arealso possible.

In some embodiments, the plurality of fibrillated fibers may have aparticular average length. In some embodiments, the average length ofthe plurality of fibrillated fibers is greater than or equal to greaterthan or equal to 0.1 mm, greater than or equal to 0.5 mm, greater thanor equal to 1 mm, greater than or equal to 2 mm, greater than or equalto 5 mm, greater than or equal to 10 mm, greater than or equal to 15 mm,or greater than or equal to 20 mm. In certain embodiments, the averagelength of the plurality of fibrillated fibers is less than or equal to25 mm, less than or equal to 20 mm, less than or equal to 15 mm, lessthan or equal to 10 mm, less than or equal to 5 mm, less than or equalto 2 mm, less than or equal to 1 mm, or less than or equal to 0.5 mmCombinations of the above-referenced ranges are possible (e.g., greaterthan or equal to 0.1 mm and less than or equal to 25 mm, greater than orequal to 1 mm and less than or equal to 15 mm). Other ranges are alsopossible.

In some embodiments, the battery component may comprise a plurality ofsynthetic fibers. Synthetic fibers may be monocomponent fibers (e.g.,polyethylene fibers, copolyester fibers) or multicomponent fibers (e.g.,bicomponent fibers). In some embodiments, the battery component includesbicomponent fibers. The bicomponent fibers may comprise a thermoplasticpolymer. Each component of the bicomponent fiber can have a differentmelting temperature. For example, the fibers can include a core and asheath where the activation temperature of the sheath is lower than themelting temperature of the core. This allows the sheath to melt prior tothe core, such that the sheath binds to other fibers in the layer, whilethe core maintains its structural integrity. The core/sheath binderfibers can be concentric or non-concentric. Other exemplary bicomponentfibers can include split fiber fibers, side-by-side fibers, and/or“island in the sea” fibers.

The synthetic fibers may comprise any suitable synthetic material.Non-limiting examples of suitable materials for the plurality ofsynthetic fibers (e.g., the monocomponent fibers, the bicomponentfibers) include polyethylene terephthalate (PET), polyethylene (PE),PET/PE (core/sheath), PET/co-PET, polyalkylenes (e.g., polyethylene,polypropylene, polybutylene), polyesters (e.g., polyethyleneterephthalate), polyamides (e.g., nylons, aramids), halogenated polymers(e.g., polytetranuoroethylenes), and combinations thereof.

In some embodiments, the plurality of synthetic fibers (e.g.,monocomponent fibers, bicomponent fibers) may be present in the batterycomponent (or in a fiber layer of the battery component) in an amountgreater than or equal to 0 wt %, greater than or equal to 1 wt %,greater than or equal to 2 wt %, greater than or equal to 3 wt %,greater than or equal to 4 wt %, greater than or equal to 5 wt %,greater than or equal to 6 wt %, greater than or equal to 7 wt %,greater than or equal to 8 wt %, or greater than or equal to 9 wt %versus the total weight of the battery component (or a fiber layer ofthe battery component). In certain embodiments, the plurality ofsynthetic fibers are present in the battery component in an amount lessthan or equal to 10 wt %, less than or equal to 9 wt %, less than orequal to 8 wt %, less than or equal to 7 wt %, less than or equal to 6wt %, less than or equal to 5 wt %, less than or equal to 4 wt %, lessthan or equal to 3 wt %, less than or equal to 2 wt %, or less than orequal to 1 wt % versus the total weight of the battery component (or afiber layer of the battery component). Combinations of the abovereferenced ranges are also possible (e.g., greater than or equal to 0 wt% and less than or equal to 10 wt %, greater than or equal to 1 wt % andless than or equal to 8 wt %, greater than or equal to 1 wt % and lessthan or equal to 4 wt %). Other ranges are also possible. In someembodiments, the battery component does not comprise synthetic fibers.

In certain embodiments, the plurality of synthetic fibers (e.g.,monocomponent fibers, bicomponent fibers) may have a particular averagefiber diameter. For example, in certain embodiments, the plurality ofsynthetic fibers may have an average fiber diameter of greater than orequal to 0.1 microns, greater than or equal to 0.5 microns, greater thanor equal to 1 micron, greater than or equal to 2 microns, greater thanor equal to 5 microns, greater than or equal to 10 microns, greater thanor equal to 15 microns, greater than or equal to 20 microns, greaterthan or equal to 25 microns, greater than or equal to 30 microns, orgreater than or equal to 40 microns. In some embodiments, the pluralityof synthetic fibers have an average fiber diameter of less than or equalto 50 microns, less than or equal to 40 microns, less than or equal to30 microns, less than or equal to 25 microns, less than or equal to 20microns, less than or equal to 15 microns, less than or equal to 10microns, less than or equal to 5 microns, less than or equal to 2microns, less than or equal to 1 micron, or less than or equal to 0.5microns. Combinations of the above referenced ranges are possible (e.g.,greater than or equal to 0.1 microns and less than or equal to 50microns, greater than or equal to 1 microns and less than or equal to 25microns). Other ranges are also possible.

In some embodiments, the plurality of synthetic fibers (e.g.,monocomponent fibers, bicomponent fibers) may have a particular averagelength. In some embodiments, the average length of the plurality ofsynthetic fibers is greater than or equal to 0.1 mm, greater than orequal to 0.5 mm, greater than or equal to 1 mm, greater than or equal to2 mm, greater than or equal to 5 mm, greater than or equal to 10 mm,greater than or equal to 15 mm, or greater than or equal to 20 mm Incertain embodiments, the average length of the plurality of syntheticfibers is less than or equal to 25 mm, less than or equal to 20 mm, lessthan or equal to 15 mm, less than or equal to 10 mm, less than or equalto 5 mm, less than or equal to 2 mm, less than or equal to 1 mm, or lessthan or equal to 0.5 mm. Combinations of the above-referenced ranges arepossible (e.g., greater than or equal to 0.1 mm and less than or equalto 25 mm, greater than or equal to 2 mm and less than or equal to 15mm). Other ranges are also possible.

In some embodiments, the battery component (or a fiber layer of thebattery component) may comprise a resin. Advantageously, theincorporation of a resin into a fiber layer as described herein mayprotect the fibers, e.g., from acid degradation, and/or may increase themechanical strength (e.g., tensile strength) of the battery component(or a fiber layer of the battery component), without substantiallyblocking the pores of the fiber layer. In certain embodiments, the resincoats at least a portion of one or more pluralities of fibers (e.g.,plurality of fine glass fibers, plurality of coarse glass fibers,plurality of fibrillated fibers) in the fiber layer. However, in someembodiments, not all fibers are coated. The extent of the coating mayvary. In some cases, the coating covers the entire fiber; though, inother cases, only a portion of the fibers is coated. In someembodiments, the resin is mixed with the fiber layer before adhering thefiber layer to a battery grid and/or before adding a paste to thebattery component.

The resin may comprise any suitable material including, but not limitedto, acrylic binder, natural rubber, acrylic, latex emulsion,styrene-acrylic, synthetic rubber (e.g., styrene-butadiene rubber),styrene acrylonitrile, and combinations thereof.

In some embodiments, the resin is free of a crosslinker.

In some embodiments, the resin is hydrophobic. The term hydrophobic, asused herein, generally refers to a material having a contact angle withwater (e.g., deionized water) of greater than 90 degrees. The contactangle of a resin may be determined by depositing a thin layer of theresin on a smooth planar substrate and curing the resin. The watercontact angle may be then measured according to the standard ASTMD5946-04. The contact angle is the angle between the substrate surfaceand the tangent line drawn to the water droplet surface at thethree-phasepoint, when a liquid drop of water is resting on a planesolid surface, measured using a contact angle goniometer. In someembodiments, the contact angle of the resin may be greater than 90degrees, may be greater than or equal to 100 degrees, greater than orequal to 110 degrees, greater than or equal to 120 degrees, greater thanor equal to 130 degrees, greater than or equal to 140 degrees, greaterthan or equal to 150 degrees, greater than or equal to 160 degrees, orgreater than or equal to 170 degrees. In certain embodiments, thecontact angle of the resin may be less than or equal to 180 degrees,less than or equal to 170 degrees, less than or equal to 160 degrees,less than or equal to 150 degrees, less than or equal to 140 degrees,less than or equal to 130 degrees, less than or equal to 120 degrees,less than or equal to 110 degrees, or less than or equal to 100 degrees.Combinations of the above-referenced ranges are possible (e.g., greaterthan or equal to 110 degrees and less than or equal to 180 degrees).Other ranges are also possible.

In certain embodiments, the resin may be present in the batterycomponent (or in a fiber layer of the battery component) in an amount ofgreater than or equal to 1 wt %, greater than or equal to 2 wt %,greater than or equal to 5 wt %, greater than or equal to 7 wt %,greater than or equal to 10 wt %, or greater than or equal to 12 wt %versus the total weight of the battery component (or the fiber layer ofthe battery component). In some embodiments, the resin may be present inthe battery component (or a fiber layer of the battery component) in anamount of less than or equal to 15 wt %, less than or equal to 12 wt %,less than or equal to 10 wt %, less than or equal to 7 wt %, less thanor equal to 5 wt %, or less than or equal to 2 wt % versus the totalweight of the battery component (or the fiber layer of the batterycomponent). Combinations of the above referenced ranges are possible(e.g., greater than or equal to 1 wt % and less than or equal to 15 wt%, greater than or equal to 1 wt % and less than or equal to 10 wt %,greater than or equalto 1 wt % and less than or equal to 5 wt %). Otherranges are also possible.

In some cases, the fiber layer or battery component with resin may becharacterized by a Cobb parameter. The Cobb parameter is generally ameasure of the water absorptiveness. Briefly, the Cobb parameter is themass of water (e.g., in grams) absorbed over 120 seconds per 1 squaremeter of the fiber layer or battery component with resin. The Cobbparameter of the fiber layer or battery component with resin may bedetermined by the TAPPI T411 om-09 standard test. In some embodiments,the Cobb parameter of the fiber layer or battery component with resin isgreater than or equal to 50 g of water per m² of sample (gsm), greaterthan or equal to 55 gsm, greater than or equal to 60 gsm, greater thanor equal to 65 gsm, greater than or equal to 70 gsm, or greater than orequal to 75 gsm. In certain embodiments, the Cobb parameter of the fiberlayer or battery component with resin is less than or equal to 80 gsm,less than or equal to 75 gsm, less than or equal to 70 gsm, less than orequal to 65 gsm, less than or equal to 60 gsm, or less than or equal to55 gsm. Combinations of the above referenced ranges are possible (e.g.,greater than or equal to 50 gsm and less than or equal to 80 gsm,greater than or equal to 50 gsm and less than or equal to 70 gsm). Otherranges are also possible.

In some embodiments a battery component (or a layer of the batterycomponent), such as a pasting paper, does not include activated carbonor conductive carbon. Such a battery component or layer may have aparticular desirable internal resistance, as determined by BCIS-03B,Rev. December 02 using a sulfuric acid bath having a specific gravity of1.280±0.005 at 80° F. In some embodiments, the internal resistance ofthe battery component (that does not include conductive carbon andactivated carbon) is greater than or equal to 0 ohm·cm², greater than orequal to 0.5 ohm·cm², greater than equal to 1 ohm·cm², greater than orequal to 2 ohm·cm², greater than or equal to 3 ohm·cm², or greater thanor equal to 4 ohm·cm². In certain embodiments, the internal resistanceof the battery component (that does not include conductive carbon andactivated carbon) is less than or equal to 5 ohm·cm², less than or equalto 4 ohm·cm², less than or equal to 3 ohm·cm², less than or equal to 2ohm·cm², less than or equal to 1 ohm·cm², less than or equal to 0.5ohm·cm², less than or equal to 0.3 ohm·cm², or less than or equal to 0.2ohm·cm². Combinations of the above-referenced ranges are also possible(e.g., greater than or equal to 0 ohm·cm² and less than or equal to 1ohm·cm², greater than or equal to 0 ohm·cm² and less than or equal to0.5 ohm·cm²). Other ranges are also possible.

In some embodiments, one or more additives may be present in the batterycomponent (or a layer of the battery component). In some embodiments,the additive comprises lead (e.g., lead oxide, red lead, lead), flockfibers, carbon, lignin, sodium sulfate, lead sulfate, sulfuric acid,water, or combinations thereof. In one set of embodiments, the additivecomprises carbon (e.g., activated carbon, conductive carbon). In someembodiments, the additives are added to a paste to form portions of thebattery component. In some embodiments, an additive may include ahydrogen suppressant as described in more detail herein. In certainembodiments, an additive may comprise a binder.

As described herein, in some embodiments, the battery component maycomprise one or more additives such as activated carbon and/orconductive carbon which can result in an increase in the conductivity ofthe battery component.

In some embodiments the additive comprises activated carbon and/orconductive carbon. Non-limiting examples of suitable types of conductivecarbon additives include carbon black, acetylene black, graphite, carbonPAN, conductive carbon fibers, and carbon nanotubes. Non-limitingexamples of suitable types of activated carbon includes carbon basedderivatives from petroleum products such a petroleum pitch, coconutshell, starches, wood-based products, and including, for example, carbonbased derivatives obtained through steam, CO₂, and/or chemicalactivation (e.g., using KOH, NaOH, or the like).

In some embodiments, the one or more additives (e.g., activated carbonand/or conductive carbon) may be added to a battery component as a layer(e.g., optional layer 7 in FIG. 1). For instance, an additive layer(e.g., conductive layer) may be formed on a surface of a fiber layer ofthe battery component. In such embodiments, the additive layer (e.g.,conductive layer) may be directly adjacent the fiber layer. In otherembodiments, one or more additives may be incorporated into a fiberlayer of the battery component (e.g., mixed into or dispersed within thefiber layer). In yet other embodiments, one or more additives may beincorporated into a fiber layer of the battery component (e.g., mixedinto or dispersed within the fiber layer) and may form an additive layer(e.g., conductive layer) on a surface of the fiber. In some embodiments,the activated carbon and/or conductive carbon may be added to thebattery component (or a fiber layer of a battery component) via acoating process, a lamination process, or by beater addition. Otherprocesses are also possible.

In some embodiments, the total amount of carbon (e.g., comprisingconductive and/or activated carbon) present within the battery componentis greater than or equal to 50 wt %, greater than or equal to 60 wt %,greater than or equal to 70 wt %, greater than or equal to 80 wt %, orgreater than or equal to 90 wt % versus the total weight of the batterycomponent. In certain embodiments, the total amount of carbon presentwithin the battery component is less than or equal to 95 wt %, less thanor equal to 90 wt %, less than or equal to 80 wt %, less than or equalto 70 wt %, or less than or equal to 60 wt % versus the total weight ofthe battery component. Combinations of the above referenced ranges arealso possible (e.g., greater than or equal to 50 wt % and less than orequal to 95 wt %, greater than or equal to 70 wt % and less than orequal to 95 wt %, greater than or equal to 80 wt % and less than orequal to 90 wt %). Other ranges are also possible.

In some embodiments, the fibers or one or more fiber layers of thebattery component is present in the battery component in the remainingweight amount not occupied by the additives (e.g., carbon, such asconductive carbon and/or activated carbon). As an illustrative example,in some embodiments, the total weight of the carbon (e.g, comprisingactivated carbon and conductive carbon) present in the battery componentis greater than 50 wt % and less than or equal to 95 wt %, and the totalweight of the fibers or fiber layer (e.g., comprising a plurality ofglass fibers, and a plurality of fibrillated fibers) present in thebattery component is greater than 5 wt % and less than or equal to 50 wt%. In some such embodiments, a plurality of tine glass fibers may bepresent in the fiber layer in an amount of greater than or equal to 30wt % and less than or equal to 60 wt % versus the total weight of thefiber layer, a plurality of course glass fibers may be present in thefiber layer in an amount of greater than or equal to 30 wt % and lessthan or equal to 60 wt % versus the total weight of the fiber layer, anda plurality of fibrillated fibers may be present in the fiber layer inan amount greater than or equal to 1 wt % and less than or equal to 15wt % versus the total weight of the fiber layer. As described herein,the fiber layer may also comprise one or more of synthetic fibers and/ora resin.

In some embodiments, conductive carbon is present within the batterycomponent (or layer) in amount of greater than or equal to 0.1 wt %,greater than or equal to 0.5 wt %, greater than or equal to 1 wt %,greater than or equal to 5 wt %, greater than or equal to 10 wt %,greater than or equal to 15 wt %, greater than or equal to 20 wt %,greater than or equal to 25 wt %, greater than or equal to 30 wt %,greater than or equal to 35 wt %, greater than or equal to 40 wt %, orgreater than or equal to 45 wt % versus the total weight of the batterycomponent. In certain embodiments, the conductive carbon is presentwithin the battery component in an amount of less than or equal to 50 wt%, less than or equal to 45 wt %, less than or equal to 40 wt %, lessthan or equal to 35 wt %, less than or equal to 30 wt %, less than orequal to 25 wt %, less than or equal to 20 wt %, less than or equal to15 wt %, less than or equal to 10 wt %, less than or equal to 5 wt %,less than or equal to 1 wt %, or less than or equal to 0.5 wt %.Combinations of the above referenced ranges are also possible (e.g.,greater than or equal to 0.1 wt % and less than or equal to 50 wt %,greater than or equal to 1 wt % and less than or equal to 30 wt %,greater than or equal to 1 wt % and less than or equal to 10 wt %).Other ranges are also possible.

In certain embodiments, activated carbon is present within the batterycomponent (or layer) in an amount greater than or equal to 0.1 wt %,greater than or equal to 0.5 wt %, greater than or equal to 1 wt %,greater than or equal to 5 wt %, greater than or equal to 10 wt %,greater than or equal to 15 wt %, greater than or equal to 20 wt %,greater than or equal to 25 wt %, greater than or equal to 30 wt %,greater than or equal to 40 wt %, greater than or equal to 50 wt %,greater than or equal to 60 wt %, greater than or equal to 70 wt %,greater than or equal to 80 wt %, greater than or equal to 85 wt %, orgreater than or equal to 90 wt % versus the total weight of the batterycomponent. In certain embodiments, the activated carbon is presentwithin the battery component in an amount less than or equal to 95 wt %,less than or equal to 90 wt %, less than or equal to 85 wt %, less thanor equal to 80 wt %, less than or equal to 70 wt %, less than or equalto 60 wt %, less than or equal to 50 wt %, less than or equal to 40 wt%, less than or equal to 30 wt %, less than or equal to 20 wt %, lessthan or equal to 15 wt %, less than or equal to 10 wt %, less than orequal to 5 wt %, less than or equal to 1 wt %, or less than or equal to0.5 wt % versus the total weight of the battery component. Combinationsof the above referenced ranges are also possible (e.g., greater than orequal to 0.1 wt % and less than or equal to 95 wt %, greater than orequal to 50 wt % and less than or equal to 95 wt %, greater than orequal to 70 wt % and less than or equal to 90 wt %). Other ranges arealso possible.

In some embodiments, both activated carbon and conductive carbon may bepresent within the battery component. The components may be present in aparticular ratio. Advantageously, an electrochemical cell comprising abattery component having a particular ratio of activated carbon toconductive carbon may have improved battery life and performance. Insome embodiments, the ratio of activated carbon to conductive carbon isgreater than or equal to 70:30, greater than or equal to 75:25, greaterthan or equal to 80:20, greater than or equal to 85:15, greater than orequal to 90:10, greater than or equal to 92:8, greater than or equal to94:6, greater than or equal to 95:5, greater than or equal to 96:4,greater than or equal to 97:3, or greater than or equal to 98:2. Incertain embodiments, the ratio of activated carbon to conductive carbonis less than or equal to 99:1, less than or equal to 98:2, less than orequal to 97:3, less than or equal to 96:4, less than or equal to 95:5,less than or equal to 94:6, less than or equal to 92:8, less than orequal to 90:10, less than or equal to 85:15, less than or equal to80:20, or less than or equal to 75:25. Combinations of the abovereferenced ranges are also possible (e.g., greater than or equal to70:30 and less than or equal to 99:1, greater than or equal to 90:10 andless than or equal to 99:1, greater than or equal to 90:10 and less thanor equal to 96:4). Other ranges are also possible.

In some embodiments, the conductive carbon may have a particularspecific surface area. In some embodiments, the specific surface area ofthe conductive carbon is greater than or equal to 1 m²/g, greater thanor equal to 5 m²/g, greater than or equal to 10 m²/g, greater than orequal to 15 m²/g, greater than or equal to 20 m²/g, greater than orequal to 30 m²/g, greater than or equal to 40 m²/g, greater than orequal to 50 m²/g, greater than or equal to 60 m²/g, greater than orequal to 65 m²/g, greater than or equal to 70 m²/g, greater than orequal to 75 m²/g, greater than or equal to 80 m²/g, greater than orequal to 85 m²/g, greater than or equal to 90 m²/g, or greater than orequal to 100 m²/g. In certain embodiments, the specific surface area ofthe conductive carbon is less than or equal to 100 m²/g, less than orequal to 90 m²/g, less than or equal to 85 m²/g, less than or equal to80 m²/g, less than or equal to 75 m²/g, less than or equal to 70 m²/g,less than or equal to 65 m²/g, less than or equal to 60 m²/g, less thanor equal to 50 m²/g, less than or equal to 40 m²/g, less than or equalto 30 m²/g, less than or equal to 20 m²/g, less than or equal to 15m²/g, less than or equal to 10 m²/g, or less than or equal to 5 m²/g.Combinations of the above reference ranges are also possible (e.g.,greater than or equal to 1 m²/g and less than or equal to 100 m²/g,greater than or equal to 40 m²/g and less than or equal to 60 m²/g).Other ranges are also possible.

In certain embodiments, the activated carbon may have a particularspecific surface area. In certain embodiments, the specific surface areaof the activated carbon is greater than or equal to 100 m²/g, greaterthan or equal to 250 m²/g, greater than or equal to 500 m²/g, greaterthan or equal to 750 m²/g, greater than or equal to 1000 m²/g, greaterthan or equal to 1500 m²/g, greater than or equal to 2000 m²/g, greaterthan or equal to 2500 m²/g, or greater than or equal to 3000 m²/g. Insome embodiments, the specific surface area of the activated carbon isless than or equal to 3500 m²/g, less than or equal to 3000 m²/g, lessthan or equal to 2500 m²/g, less than or equal to 2000 m²/g, less thanor equal to 1500 m²/g, less than or equal to 1000 m²/g, less than orequal to 750 m²/g, less than or equal to 500 m²/g. or less than or equalto 250 m²/g. Combinations of the above-referenced ranges are alsopossible (e.g., greater than or equal to 100 m²/g and less than or equalto 3500 m²/g, greater than or equal to 1000 m²/g and less than or equalto 2500 m²/g,). Other ranges are also possible.

In some embodiments, the total carbon present in the battery componentis greater than or equal to 80 wt % and less than or equal to 90 wt %and the ratio of activated carbon to conductive carbon is greater thanor equal to 90:10 and less than or equal to 99:1 (e.g., greater than orequal to 90:10 and less than or equal to 96:4).

A battery component comprising one or more additives includingconductive carbon and activated carbon may have a particular internalresistance. The internal resistance of the battery component includingconductive carbon and activated carbon may be measured using the IEC62576 standard (2009) constant current method by using a symmetric supercapacitor having two identical battery components in a symmetric supercapacitor assembly. In this method, an Equivalent Series Resistance(ESR) value (in ohm), when charging/discharging the supercapacitor withthe constant current, can be calculated from the value of voltagejump/drop, when the current direction changes from discharge to chargeor charge to discharge using the equation:ESR=U_(jump/drop)/Iwhere, I is the constant current of charging/discharging andU_(jump/drop) is the change in potential when the direction changes fromcharge to discharge or from discharge to charge.

In some embodiments, the internal resistance of the battery componentincluding conductive carbon and activated carbon is greater than orequal to 0 ohm·cm², greater than or equal to 0.5 ohm·cm², greater thanequal to 1 ohm·cm², greater than or equal to 2 ohm·cm², greater than orequal to 3 ohm·cm², greater than or equal to 4 ohm·cm², greater than orequal to 5 ohm·cm², greater than equal to 6 ohm·cm², greater than orequal to 7 ohm·cm², greater than or equal to 8 ohm·cm², or greater thanor equal to 9 ohm·cm². In certain embodiments, the internal resistanceof the battery component including conductive carbon and activatedcarbon is less than or equal to 10 ohm·cm², less than or equal to 9ohm·cm², less than or equal to 8 ohm·cm², less than or equal to 7ohm·cm², less than or equal to 6 ohm·cm², less than or equal to 5ohm·cm², less than or equal to 4 ohm·cm², less than or equal to 3ohm·cm², less than or equal to 2 ohm·cm², less than or equal to 1ohm·cm², or less than or equal to 0.5 ohm·cm². Combinations of theabove-referenced ranges are also possible (e.g., greater than or equalto 0 ohm·cm² and less than or equal to 10 ohm·cm², greater than or equalto 0 ohm ·cm² and less than or equal to 2 ohm·cm²). Other ranges arealso possible.

In some embodiments, a battery component comprising one or moreadditives may include a hydrogen suppressant. Non-limiting examples ofhydrogen suppressants include oxides, hydroxides, sulfates (e.g.,sulfates of lead, zinc, cadmium, bismuth, and/or silver), tin, titanium,cobalt, antimony, and combinations thereof. The hydrogen suppressantsmay be present in the battery component in any suitable amount. In someembodiments, the hydrogen suppressant is present in the batterycomponent (or layer) in an amount of greater than or equal to 0.1 wt %,greater than or equal to 0.2 wt %, greater than or equal to 0.3 wt %,greater than or equal to 0.4 wt %, greater than or equal to 0.5 wt %,greater than or equal to 0.6 wt %, greater than or equal to 0.8 wt %,greater than or equal to 1 wt %, greater than or equal to 1.2 wt %,greater than or equal to 1.5 wt %, or greater than or equal to 1.7 wt %.In certain embodiments, the hydrogen suppressant is present in thebattery component (or layer) in an amount less than or equal to 2 wt %,less than or equal to 1.7 wt %, less than or equal to 1.5 wt %, lessthan or equal to 1.2 wt %, less than or equal to 1 wt %, less than orequal to 0.8 wt %, less than or equal to 0.6 wt %, less than or equal to0.5 wt %, less than or equal to 0.4 wt %, less than or equal to 0.3 wt%, or less than or equal to 0.2 wt %. Combinations of theabove-referenced ranges are possible (e.g., greater than or equal to 0.1wt % and less than or equal to 2 wt %, greater than or equal to 0.5 wt %and less than or equal to 2 wt %). Other ranges are also possible. Insome embodiments, the hydrogen suppressant is present in a batterycomponent that includes conductive carbon and/or activated carbon, suchas in the amounts described herein.

In certain embodiments, a battery component comprising one or moreadditives including conductive carbon and activated carbon may includeone or more binders (e.g., to bind the conductive carbon and/oractivated carbon together). Non-limiting examples of suitable bindermaterials include polytetrafluoroethylene (PTFE), carboxymethylcellulose(CMC), styrene-butadiene (SBR), acrylic, polyvinylidene fluoride (PVDF),or the like. The binder may be useful for, for example, binding theconductive carbon and/or the activated carbon to at least a portion ofthe plurality of fibers in the fiber layer. The binder may compriseparticles and/or may be in liquid form when applied to the batterycomponent.

In some embodiments, the binder is present within the battery component(or layer) in amount of greater than or equal to 1 wt %, greater than orequal to 5 wt %, greater than or equal to 10 wt %, greater than or equalto 20 wt %, greater than or equal to 30 wt %, or greater than or equalto 40 wt % versus the total weight of the battery component. In certainembodiments, the binder is present within the battery component (orlayer) in an amount of less than or equal to 50 wt %, less than or equalto 40 wt %, less than or equal to 30 wt %, less than or equal to 20 wt%, less than or equal to 10 wt %, less than or equal to 5 wt %, or lessthan or equal to 2 wt %. Combinations of the above referenced ranges arealso possible (e.g., greater than or equal to 1 wt % and less than orequal to 50 wt %, greater than or equal to 1 wt % and less than or equalto 30 wt %, greater than or equal to 1 wt % and less than or equal to 20wt %). Other ranges are also possible.

In an exemplary embodiment, the battery component comprises a pluralityof fine glass fibers having an average fiber diameter of less than 2microns, a plurality of coarse glass fibers having an average fiberdiameter of greater than or equal to 2 microns, and a plurality offibrillated fibers. In some embodiments, the plurality of fine glassfibers are present in an amount greater than or equal to 30 wt % andless than or equal to 60 wt % versus the total weight of the batterycomponent. In certain embodiments, the plurality of coarse glass fibersare present in an amount greater than or equal to 30 wt % and less thanor equal to 60 wt % versus the total weight of the battery component. Insome cases, the plurality of fibrillated fibers may be present in anamount greater than or equal to 1 wt % and less than or equal to 15 wt %versus the total weight of the battery component.

In some embodiments described above and/or herein, the battery componentcomprises a resin present in an amount greater than or equal to 1 wt %and less than or equal to 10 wt % versus the total weight of the batterycomponent. The resin may be a hydrophobic resin. In certain embodiments,the battery component comprises a plurality of bicomponent fiberspresent in an amount of greater than 0 wt % (e.g., at least 1 wt %) andless than or equal to 8 wt % versus the total weight of the batterycomponent. In some embodiments, the battery component has a specificsurface area of greater than or equal to 0.2 m²/g and less than or equalto 5 m²/g. The battery component may have a mean pore size of greaterthan or equal to 0.1 microns and less than or equal to 15 microns. Insome embodiments, the battery component has a dry tensile strength ofgreater than or equal to 0.1 pounds per inch and less than or equal to15 pounds per inch. In some embodiments, the battery component has anair permeability of greater than or equal to 0.1 CFM and less than orequal to 1000 CFM.

In another exemplary embodiment, the battery component comprises a fiberlayer, activated carbon and conductive carbon. The fiber layer comprisesa plurality of fine glass fibers having an average fiber diameter ofless than 2 microns, wherein the plurality of fine glass fibers arepresent in an amount greater than or equal to 30 wt % and less than orequal to 60 wt % versus the total weight of the fiber layer. The fiberlayer also comprises a plurality of coarse glass fibers having anaverage fiber diameter of greater than or equal to 2 microns, whereinthe plurality of coarse glass fibers are present in an amount greaterthan or equal to 30 wt % and less than or equal to 60 wt % versus thetotal weight of the fiber layer. The fiber layer also comprises aplurality of fibrillated fibers present in an amount greater than orequal to 1 wt % and less than or equal to 15 wt % versus the totalweight of the fiber layer. In some embodiments, the ratio of activatedcarbon to conductive carbon is greater than or equal to 90:10 and lessthan or equal to 99:1. In some embodiments, the activated carbon and/orconductive carbon is present within the fiber layer. Additionally oralternatively, the battery component comprises a second layer adjacentthe fiber layer comprising the activated carbon and the conductivecarbon.

In some embodiments described above and/or herein, the fiber layercomprises a resin present in an amount greater than or equal to 1 wt %and less than or equal to 10 wt % versus the total weight of the fiberlayer. In certain embodiments, the resin is hydrophobic. In certainembodiments, the fiber layer comprises a plurality of bicomponent fiberspresent in an amount of greater than 0 wt % and less than or equal to 8wt % versus the total weight of the fiber layer. In some embodiments,the battery component has a specific surface area of greater than orequal to 0.2 m²/g and less than or equal to 5 m²/g, in some cases, thebattery component may have a mean pore size of greater than or equal to0.1 microns and less than or equal to 15 microns. The battery componentmay have a dry tensile strength of greater than or equal to 0.1 poundsper inch and less than or equal to 15 pounds per inch. In someembodiments, the battery component has an air permeability of greaterthan or equal to 0.1 CFM and less than or equal to 1000 CFM.

In some cases, the battery component described herein (e.g., a batterycomponent including a plurality of glass fibers and a plurality offibrillated fibers described herein) may be relatively easy to processand/or may have desirable mechanical strength characteristics. The easeof processing and/or mechanical strength characteristics may beinfluenced by, at least in part, the dry tensile strength of the batterycomponent (e.g., provided at least in part by the plurality offibrillated fibers). In some embodiments, the dry tensile strength ofthe battery component is greater than or equal to 0.1 lbs. per inch,greater than or equal to 0.2 lbs. per inch, greater than or equal to 0.5lbs. per inch, greater than or equal to 1 lb. per inch, greater than orequal to 2 lbs. per inch, greater than or equal to 5 lbs. per inch,greater than or equal to 7 lbs. per inch, greater than or equal to 10lbs. per inch, or greater than or equal to 12 lbs. per inch. In certainembodiments, the dry tensile strength of the battery component is lessthan or equal to 15 lbs. per inch, less than or equal to 12 lbs. perinch, less than or equal to 10 lbs. per inch, less than or equal to 7lbs. per inch. less than or equal to 5 lbs. per inch, less than or equalto 2 lbs. per inch, less than or equal to 1 lb. per inch, less than orequal to 0.5 lbs. per inch, or less than or equal to 0.2 lbs. per inch.Combinations of the above referenced ranges are possible (e.g., greaterthan or equal to 0.1 lbs. per inch and less than or equal to 15 lbs. perinch, greater than or equal to 0.5 lbs. per inch and less than or equalto 7 lbs. per inch). Other ranges are also possible. Dry tensilestrength is measured in the machine direction and is determinedaccording to BCIS 03A, Rev. December 2015, Method 9.

In certain embodiments, a battery component including a fiber layerdescribed herein may exhibit improved adhesion to an electrode orbattery grid (e.g., within a pasting paper application). Improvedadhesion may be influenced by, at least in part, the mean pore size ofthe battery component.

Mean pore size, as used herein, is measured using the liquid porosimetrymethod (PMI capillary flow porometer) described in BCIS-03A, Rev.September 09, Method 6. In some embodiments, the mean pore size of thebattery component is greater than or equal to 0.1 microns, greater thanor equal to 0.2 microns, greater than or equal to 0.5 microns, greaterthan or equal to 1 micron, greater than or equal to 2 microns, greaterthan or equal to 5 microns, or greater than or equal to 10 microns. Incertain embodiments, the mean pore size of the battery component is lessthan or equal to 15 microns, less than or equal to 10 microns, less thanor equal to 5 microns, less than or equal to 2 microns, less than orequal to 1 micron, less than or equal to 0.5 microns, or less than orequal to 0.2 microns. Combinations of the above referenced ranges arepossible (e.g., greater than or equal to 0.1 microns and less than orequal to 15 microns, greater than or equal to 0.5 microns and less thanor equal to 10 microns). Other ranges are also possible.

As noted above, in some embodiments, a battery component describedherein (e.g., a battery component including a plurality of glass fibersand a plurality of fibrillated fibers) may have a desirable resistanceto acid stratification. The desirable resistance to acid stratificationmay be influenced by, at least in part, the specific surface area of thebattery component. In certain embodiments, the specific surface area ofthe battery component is greater than or equal to 0.2 m²/g, greater thanor equal to 0.5 m²/g, greater than or equal to 1 m²/g, greater than orequal to 1.5 m²/g, greater than or equal to 2 m²/g, greater than orequal to 3 m²/g, or greater than or equal to 4 m²/g. In someembodiments, the specific surface area of the battery component is lessthan or equal to 5 m²/g, less than or equal to 4 m²/g, less than orequal to 3 m²/g, less than or equal to 2 m²/g, less than or equal to 1.5m²/g, less than or equal to 1 m²/g, or less than or equal to 0.5 m²/g.Combinations of the above referenced ranges are possible (e.g., greaterthan or equal to 0.2 m²/g and less than or equal to 5 m²/g, greater thanor equal to 0.5 m²/g and less than or equal to 3 m²/g). Other ranges arealso possible. The specific surface area (BET surface area) is measuredaccording to section 10 of Battery Council international StandardBCIS-03A, “Recommended Battery Materials Specifications Valve RegulatedRecombinant Batteries”, method 8-September 2009 being “Standard TestMethod for Surface Area of Recombinant Battery Separator Mat”. Followingthis technique, the BET surface area is measured via adsorption analysisusing a BET surface analyzer (e.g., Micromeritics Gemini III 2375Surface Area Analyzer) with nitrogen gas; the sample amount is between0.5 and 0.6 grams in a ¾ tube; and the sample is allowed to degas at 75degrees C. for a minimum of 3 hours.

In some embodiments, the battery component may have a particular basisweight. For instance, in certain embodiments, the battery component mayhave a basis weight of less than or equal to 200 g/m², less than orequal to 175 g/m², less than or equal to 150 g/m², less than or equal to125 g/m², less than or equal to 100 g/m², less than or equal to 75 g/m²,less than or equal to 50 g/m², less than or equal to 25 g/m², or lessthan or equal to 15 g/m². In some embodiments, the battery component mayhave a basis weight of greater than or equal to 10 g/m², greater than orequal to 15 g/m², greater than or equal to 25 g/m², greater than orequal to 50 g/m², greater than or equal to 75 g/m², greater than orequal to 100 g/m², greater than or equal to 125 g/m², greater than orequal to 150 g/m², or greater than or equal to 175 g/m². Combinations ofthe above referenced ranges are possible (e.g., greater than or equal to10 g/m² and less than or equal to 200 g/m², greater than or equal to 15g/m² and less than or equal to 100 g/m²). Other ranges are alsopossible. The basis weight may be determined according to standardBCIS-03A, September-09, Method 3.

In some embodiments, the battery component may be relatively thin. Forexample, in some embodiments, the battery component has a thickness ofless than or equal to 0.6 mm, less than or equal to 0.5 mm, less than orequal to 0.4 mm, less than or equal to 0.3 mm, or less than or equal to0.2 mm. In certain embodiments, the battery component has a thickness ofgreater than or equal to 0.1 mm, greater than or equal to 0.2 mm,greater than or equal to 0.3 mm, greater than or equal to 0.4 mm, orgreater than or equal to 0.5 mm. Combinations of the above referencedranges are also possible (e.g., greater than or equal to 0.1 mm and lessthan or equal to 0.6 mm, greater than or equal to 0.1 mm and less thanor equal to 0.3 mm). Other ranges are also possible. The thickness maybe determined according to standard BCIS-03A, September-09, Method 10.

In some cases, the battery component may have a particular mean poresize. In some embodiments, the mean pore size of the battery componentmay be greater than or equal to 0.1 microns, greater than or equal to0.2 microns, greater than or equal to 0.5 microns, greater than or equalto 1 micron, greater than or equal to 2 microns, greater than or equalto 5 microns, greater than or equal to 8 microns, greater than or equalto 10 microns, or greater than or equal to 12 microns. In certainembodiments, the mean pore size of the battery component may be lessthan or equal to 15 microns, less than or equal to 12 microns, less thanor equal to 10 microns, less than or equal to 8 microns, less than orequal to 5 microns, less than or equal to 2 microns, less than or equalto 1 micron, less than or equal to 0.5 microns, or less than or equal to0.2 microns. Combinations of the above referenced ranges are alsopossible (e.g., greater than or equal to 0.1 microns and less than orequal to 15 microns, greater than or equal to 0.5 microns and less thanor equal to 10 microns). The mean pore size may be measured using liquidporosimetry method (PMI capillary Flow porometer) described in BCIS-03A,Rev. September 09, Method 6.

In some cases, the battery component may have a particular maximum poresize. In some embodiments, the maximum pore size of the batterycomponent may be greater than or equal to 5 microns, greater than orequal to 10 microns, greater than or equal to 15 microns, greater thanor equal to 20 microns, greater than or equal to 30 microns, greaterthan or equal to 50 microns, greater than or equal to 70 microns, orgreater than or equal to 90 microns. In certain embodiments, the maximumpore size of the battery component may be less than or equal to 100microns, less than or equal to 90 microns, less than or equal to 70microns, less than or equal to 50 microns, less than or equal to 30microns, less than or equal to 20 microns, less than or equal to 15microns, or less than or equal to 10 microns. Combinations of the abovereferenced ranges are also possible (e.g., greater than or equal to 5microns and less than or equal to 100 microns, greater than or equal to15 microns and less than or equal to 70 microns). The maximum pore sizemay be measured using liquid porosimetry method (PMI capillary Flowporometer) described in BCIS-03A, Rev. September 09, Method 6.

In certain embodiments, the battery component may be designed to havedesirable air permeability. In some embodiments, the air permeability ofthe battery component may be greater than or equal to 0.1 CFM, greaterthan or equal to 0.5 CFM, greater than or equal to 1 CFM, greater thanor equal to 2 CFM, greater than or equal to 5 CFM, greater than or equalto 10 CFM, greater than or equal to 25 CFM, greater than or equal to 50CFM, greater than or equal to 75 CFM, greater than or equal to 100 CFM,greater than or equal to 250 CFM, greater than or equal to 500 CFM, orgreater than or equal to 750 CFM. In certain embodiments, the airpermeability of the battery component may be less than or equal to 1000CFM, less than or equal to 750 CFM, less than or equal to 500 CFM, lessthan or equal to 250 CFM, less than or equal to 100 CFM, less than orequal to 75 CFM, less than or equal to 50 CFM, less than or equal to 25CFM, less than or equal to 10 CFM, less than or equal to 5 CFM, lessthan or equal to 2 CFM, less than or equal to 1 CFM, or less than orequal to 0.5 CFM. Combinations of the above reference ranges are alsopossible (e.g., greater than or equal to 0.1 CFM and less than or equalto 1000 CFM, greater than or equal to 0.5 CFM and less than 100 CFM).Other ranges are also possible. Air permeability may be determinedaccording to TAPPI Method T251.

As described herein, in some embodiments, a battery component describedherein may be a capacitance layer (e.g., comprising conductive carbon)that can be used in an electrochemical cell. In some embodiments, thecapacitance layer comprises a plurality of fibers (e.g., glass fibers,synthetic fibers, fibrillated fibers, cellulosic (or derivativesthereof) fibers, carbon fibers, and/or combinations thereof), activatedcarbon, conductive carbon, and a binder. Other components may also bepresent.

In some embodiments, the activated carbon and conductive carbon may beimpregnated within the plurality of fibers (e.g., within a fiber layer).For example, as illustrated in FIG. 2, in some embodiments, a layer 20comprises a plurality of fibers 25, and a conductive carbon 30 and anactivated carbon 30 impregnated within plurality of fibers 25. The layermay be used as a conductive layer or capacitance layer.

In certain embodiments, the activated carbon and conductive carbon maybe mixed with a binder to form a mixture (e.g., to form capacitor ink ordough). The mixture may then be incorporated into/onto a plurality offibers (e.g., in a fiber layer) by saturating the plurality of fiberswith the mixture and/or coating the mixture on top of a fiber layercomprising the plurality of fibers. For example, referring to FIG. 1,the battery component 5 (e.g., a capacitance layer) may comprise fiberlayer 6 comprising a plurality of fibers and optional layer 7 which maybe, in some such embodiments, a coating comprising the mixture ofactivated carbon and conductive carbon, binder, and optionally, ahydrogen suppressant and/or other additives or components. Methods forcoating a layer are described in more detail herein.

In some embodiments, the capacitance layer can be positioned adjacent(e.g., directly adjacent) to, for example, either or both sides of acomponent of a battery such as a separator and/or an electrode, withoutcarbon impregnation into the separator and/or electrode. In someembodiments, the separator and capacitance layer may be incorporatedinto the battery during battery assembly. In certain embodiments, theseparator may be directly adjacent with a plate (e.g., a positive plate,a negative plate) such that the separator is present between thecapacitance layer and the plate (i.e., the capacitance layer is notdirectly adjacent the plate).

In some embodiments, the capacitance layer comprises a total amount offibers in an amount of greater than or equal to 0 wt % and less than orequal to 95 wt % versus the total weight of the capacitance layer. Insome embodiments, the fibers include one or more of glass fibers,synthetic fibers, fibrillated fibers, cellulosic (or derivativesthereof) fibers, and carbon fibers. In some embodiments, the pluralityof fibers is present in the capacitance layer in an amount of greaterthan or equal to 0 wt %, greater than or equal to 5 wt %, greater thanor equal to 10 wt %, greater than or equal to 15 wt %, greater than orequal to 20 wt %, greater than or equal to 25 wt %, greater than orequal to 30 wt %, greater than or equal to 35 wt %, greater than orequal to 40 wt %, greater than or equal to 45 wt %, greater than orequal to 50 wt %, greater than or equal to 55 wt %, greater than orequal to 60 wt %, greater than or equal to 65 wt %, greater than orequal to 70 wt %, greater than or equal to 75 wt %, greater than orequal to 80 wt %, greater than or equal to 85 wt %, or greater than orequal to 90 wt % versus the total weight of the capacitance layer. Incertain embodiments, the plurality of fibers is present in thecapacitance layer in an amount of less than or equal to 95 wt %, lessthan or equal to 90 wt %, less than or equal to 85 wt %, less than orequal to 80 wt %, less than or equal to 75 wt %, less than or equal to70 wt %, less than or equal to 65 wt %, less than or equal to 60 wt %,less than or equal to 55 wt %, less than or equal to 50 wt %, less thanor equal to 45 wt %, less than or equal to 40 wt %, less than or equalto 35 wt %, less than or equal to 30 wt %, less than or equal to 25 wt%, less than or equal to 20 wt %, less than or equal to 15 wt %, lessthan or equal to 10 wt %, or less than or equal to 5 wt %. Combinationsof the above-referenced ranges are possible (e.g., greater than or equalto 0 wt % and less than or equal to 95 wt %, greater than or equal to 85wt % and less than or equal to 95 wt %, greater than or equal to 90 wt %and less than or equal to 95 wt %, greater than or equal to 80 wt % andless than or equal to 95 wt %, greater than or equal to 5 wt % and lessthan or equal to 50 wt %, greater than or equal to 5 wt % and less thanor equal to 20 wt %). Other ranges are also possible.

In an exemplary embodiments, the capacitance layer comprises a pluralityof glass fibers. In some embodiments, the plurality of glass fibers ispresent in the capacitance layer in an amount of greater than or equalto 0 wt %, greater than or equal to 5 wt %, greater than or equal to 10wt %, greater than or equal to 15 wt %, greater than or equal to 20 wt%, greater than or equal to 25 wt %, greater than or equal to 30 wt %,greater than or equal to 35 wt %, greater than or equal to 40 wt %,greater than or equal to 45 wt %, greater than or equal to 50 wt %,greater than or equal to 55 wt %, greater than or equal to 60 wt %,greater than or equal to 65 wt %, greater than or equal to 70 wt %,greater than or equal to 75 wt %, greater than or equal to 80 wt %,greater than or equal to 85 wt %, or greater than or equal to 90 wt %versus the total weight of the capacitance layer. In certainembodiments, the plurality of glass fibers is present in the capacitancelayer in an amount of less than or equal to 95 wt %, less than or equalto 90 wt %, less than or equal to 85 wt %, less than or equal to 80 wt%, less than or equal to 75 wt %, less than or equal to 70 wt %, lessthan or equal to 65 wt %, less than or equal to 60 wt %, less than orequal to 55 wt %, less than or equal to 50 wt %, less than or equal to45 wt %, less than or equal to 40 wt %, less than or equal to 35 wt %,less than or equal to 30 wt %, less than or equal to 25 wt %, less thanor equal to 20 wt %, less than or equal to 15 wt %, less than or equalto 10 wt %, or less than or equal to 5 wt %. Combinations of theabove-referenced ranges are possible (e.g., greater than or equal to 0wt % and less than or equal to 95 wt %, greater than or equal to 85 wt %and less than or equal to 95 wt %, greater than or equal to 90 wt % andless than or equal to 95 wt %, greater than or equal to 80 wt % and lessthan or equal to 95 wt %, greater than or equal to 5 wt % and less thanor equal to 50 wt %, greater than or equal to 5 wt % and less than orequal to 20 wt %). Other ranges are also possible.

In some embodiments, the plurality of fibers are selected from the groupconsisting of glass fibers, synthetic fibers, fibrillated fibers,cellulosic (or derivatives thereof) fibers, carbon fibers, andcombinations thereof. In a particular embodiment, the capacitance layercomprises a plurality of glass fibers. Advantageously, capacitancelayers comprising a plurality of glass fibers may have desirableproperties including, but not limited to, increased battery lifetimeandlor ease of manufacturing (e.g., during incorporation of acapacitance layer as a separate layer adjacent an electrode) as comparedto certain existing cells in which capacitance particles (e.g.,comprising carbon) are mixed with electroactive materials.

For example, in some embodiments, the plurality of fibers comprises aplurality of fine glass fibers and a plurality of coarse glass fibers.in some embodiments, the ratio of fine glass fibers to coarse glassfibers in the capacitance layer may be greater than or equal to 10:90,greater than or equal to 15:85, greater than or equal to 20:80, greaterthan or equal to 25:75, greater than or equal to 30:70, greater than orequal to 35:65, greater than or equal to 40:60, greater than or equal to45:55, greater than or equal to 50:50, greater than or equal to 55:45,greater than or equal to 60:40, greater than or equal to 65:35, greaterthan or equal to 70:30, greater than or equal to 75:25, greater than orequal to 80:20, or greater than or equal to 85:15. In certainembodiments, the ratio of fine glass fibers to coarse glass fibers inthe capacitance layer may be less than or equal to 90:10, less than orequal to 85:15, less than or equal to 80:20, less than or equal to75:25, less than or equal to 70:30, less than or equal to 65:35, lessthan or equal to 60:40, less than or equal to 55:45, less than or equalto 50:50, less than or equal to 45:55, less than or equal to 40:60, lessthan or equal to 35:65, less than or equal to 30:70, less than or equalto 25:75, less than or equal to 20:80, or less than or equal to 15:85.Combinations of the above referenced ranges are possible (e.g., greaterthan or equal to 10:90 and less than or equal to 90:10). Other rangesare also possible. In some embodiments, the fine glass fibers aremicroglass fibers and the coarse glass fibers are chopped strand fibers.

In some embodiments, capacitance layers having a particular ratio ofactivated carbon to conductive carbon may have desirable propertiesincluding, but not limited to, improved battery performance (e.g.,including substantially instantaneous production of current upon initialdischarge of the battery) and improved battery life. In someembodiments, the ratio of activated carbon to conductive carbon in thecapacitance layer is greater than or equal to 70:30, greater than orequal to 72:28, greater than or equal to 75:25, greater than or equal to77:23, greater than or equal to 80:20, greater than or equal to 82:18,greater than or equal to 85:15, greater than or equal to 87:13, greaterthan or equal to 90:10, greater than or equal to 90.5:9.5, greater thanor equal to 91:9, greater than or equal to 91.5:8.5, greater than orequal to 92:8, greater than or equal to 92.5:7.5, greater than or equalto 93:7, greater than or equal to 93.5:6.5, greater than or equal to94:6, greater than or equal to 94.5:5.5, greater than or equal to 95:5,greater than or equal to 95.5:4.5, greater than or equal to 96:4,greater than or equal to 96.5:3.5, greater than or equal to 97:3,greater than or equal to 97.5:2.5, greater than or equal to 98:2,greater than or equal to 98.5:1.5, or greater than or equal to 99:1. Incertain embodiments, the ratio of activated carbon to conductive carbonin the capacitance layer is less than or equal to 99.5:0.5, less than orequal to 99:1, less than or equal to 98.5:1.5, less than or equal to98:2, less than or equal to 97.5:2.5, less than or equal to 97:3, lessthan or equal to 96.5:3.5, less than or equal to 96:4, less than orequal to 95.5:4.5, less than or equal to 95:5, less than or equal to94.5:5.5, less than or equal to 94:6, less than or equal to 93.5:6.5,less than or equal to 93:7, less than or equal to 92.5:7.5, less than orequal to 92:8, less than or equal to 91.5:8.5, less than or equal to91:9, less than or equal to 90.5:9.5, less than or equal to 90:10, lessthan or equal to 87:13, less than or equal to 85:15, less than or equalto 82:18, less than or equal to 80:20, less than or equal to 77:23, lessthan or equal to 75:25, or less than or equal to 72:28. Combinations ofthe above referenced ranges are also possible (e.g., greater than orequal to 70:30 and less than or equal to 99:1, greater than or equal to90:10 and less than or equal to 99:1, greater than or equal to 90:10 andless than or equal to 96:4). Other ranges are also possible.

In some embodiments, the total amount of carbon (e.g., comprisingconductive and/or activated carbon) present within the capacitance layeris greater than or equal to 5 wt %, greater than or equal to 10 wt %,greater than or equal to 15 wt %, greater than or equal to 20 wt %,greater than or equal to 25 wt %, greater than or equal to 30 wt %,greater than or equal to 35 wt %, greater than or equal to 40 wt %,greater than or equal to 45 wt %, greater than or equal to 50 wt %,greater than or equal to 55 wt %, greater than or equal to 60 wt %,greater than or equal to 65 wt %, greater than or equal to 70 wt %,greater than or equal to 75 wt %, greater than or equal to 80 wt %,greater than or equal to 84 wt %, greater than or equal to 85 wt %, orgreater than or equal to 90 wt % versus the total weight of thecapacitance layer. In certain embodiments, the total amount of carbonpresent within the capacitance layer is less than or equal to 95 wt %,less than or equal to 90 wt %, less than or equal to 85 wt %, less thanor equal to 84 wt %, less than or equal to 80 wt %, less than or equalto 75 wt %, less than or equal to 70 wt %, less than or equal to 65 wt%, less than or equal to 60 wt %, less than or equal to 55 wt %, lessthan or equal to 50 wt %, less than or equal to 45 wt %, less than orequal to 40 wt %, less than or equal to 35 wt %, less than or equal to30 wt %, less than or equal to 25 wt %, less than or equal to 20 wt %,less than or equal to 15 wt %, or less than or equal to 10 wt % versusthe total weight of the capacitance layer. Combinations of the abovereferenced ranges are also possible (e.g., greater than or equal to 5 wt% and less than or equal to 95 wt %, greater than or equal to 50 wt %and less than or equal to 95 wt %, greater than or equal to 70 wt % andless than or equal to 95 wt %). Other ranges are also possible.

In some embodiments, conductive carbon is present within the capacitancelayer in an amount of greater than or equal to 1 wt %, greater than orequal to 5 wt %, greater than or equal to 10 wt %, greater than or equalto 15 wt %, greater than or equal to 20 wt %, greater than or equal to25 wt %, greater than or equal to 30 wt %, greater than or equal to 35wt %, greater than or equal to 40 wt %, or greater than or equal to 45wt % versus the total weight of the capacitance layer. In certainembodiments, the conductive carbon is present within the capacitancelayer in an amount of less than or equal to 50 wt %, less than or equalto 45 wt %, less than or equal to 40 wt %, less than or equal to 35 wt%, less than or equal to 30 wt %, less than or equal to 25 wt %, lessthan or equal to 20 wt %, less than or equal to 15 wt %, less than orequal to 10 wt %, or less than or equal to 5 wt % versus the totalweight of the capacitance layer. Combinations of the above referencedranges are also possible (e.g., greater than or equal to I wt % and lessthan or equal to 50 wt %, greater than or equal to 1 wt % and less thanor equal to 20 wt %, greater than or equal to 1 wt % and less than orequal to 10 wt %). Other ranges are also possible.

In some embodiments, conductive carbon is present within the capacitancelayer in amount of greater than or equal to 1 wt %, greater than orequal to 5 wt %, greater than or equal to 10 wt %, greater than or equalto 15 wt %, greater than or equal to 20 wt %, greater than or equal to25 wt %, greater than or equal to 30 wt %, greater than or equal to 35wt %, greater than or equal to 40 wt %, or greater than or equal to 45wt % versus the total weight of carbon present in the capacitance layer.In certain embodiments, the conductive carbon is present within thecapacitance layer in an amount of less than or equal to 50 wt %, lessthan or equal to 45 wt %, less than or equal to 40 wt %, less than orequal to 35 wt %, less than or equal to 30 wt %, less than or equal to25 wt %, less than or equal to 20 wt %, less than or equal to 15 wt %,less than or equal to 10 wt %, or less than or equal to 5 wt % versusthe total weight of carbon present in the capacitance layer.Combinations of the above referenced ranges are also possible (e.g.,greater than or equal to 1 wt % and less than or equal to 50 wt %,greater than or equal to 1 wt % and less than or equal to 20 wt %,greater than or equal to 1 wt % and less than or equal to 10 wt %).Other ranges are also possible.

In some embodiments, activated carbon is present within the capacitancelayer in amount of greater than or equal to 5 wt %, greater than orequal to 10 wt %, greater than or equal to 15 wt %, greater than orequal to 20 wt %, greater than or equal to 25 wt %, greater than orequal to 30 wt %, greater than or equal to 35 wt %, greater than orequal to 40 wt %, greater than or equal to 45 wt %, greater than orequal to 50 wt %, greater than or equal to 55 wt %, greater than orequal to 60 wt %, greater than or equal to 65 wt %, greater than orequal to 70 wt %, greater than or equal to 75 wt %, greater than orequal to 80 wt %, greater than or equal to 85 wt %, or greater than orequal to 90 wt % versus the total weight of the capacitance layer. Incertain embodiments, the activated carbon is present within thecapacitance layer in an amount of less than or equal to 95 wt %, lessthan or equal to 90 wt %, less than or equal to 85 wt %, less than orequal to 80 wt %, less than or equal to 75 wt %, less than or equal to70 wt %, less than or equal to 65 wt %, less than or equal to 60 wt %,less than or equal to 55 wt %, less than or equal to 50 wt %, less thanor equal to 45 wt %, less than or equal to 40 wt %, less than or equalto 35 wt %, less than or equal to 30 wt %, less than or equal to 25 wt%, less than or equal to 20 wt %, less than or equal to 15 wt %, or lessthan or equal to 10 wt % versus the total weight of the capacitancelayer. Combinations of the above referenced ranges are also possible(e.g., greater than or equal to 1 wt % and less than or equal to 95 wt%, greater than or equal to 50 wt % and less than or equal to 95 wt %,greater than or equal to 70 wt % and less than or equal to 90 wt %).Other ranges are also possible.

In some embodiments, activated carbon is present within the capacitancelayer in amount of greater than or equal to 1 wt %, greater than orequal to 5 wt %, greater than or equal to 10 wt %, greater than or equalto 15 wt %, greater than or equal to 20 wt %, greater than or equal to25 wt %, greater than or equal to 30 wt %, greater than or equal to 35wt %, greater than or equal to 40 wt %, greater than or equal to 45 wt%, greater than or equal to 50 wt %, greater than or equal to 55 wt %,greater than or equal to 60 wt %, greater than or equal to 65 wt %,greater than or equal to 70 wt %, greater than or equal to 75 wt %,greater than or equal to 80 wt %, greater than or equal to 85 wt %, orgreater than or equal to 90 wt % versus the total weight of carbonpresent in the capacitance layer. In certain embodiments, the activatedcarbon is present within the capacitance layer in an amount of less thanor equal to 95 wt %, less than or equal to 90 wt %, less than or equalto 85 wt %, less than or equal to 80 wt %, less than or equal to 75 wt%, less than or equal to 70 wt %, less than or equal to 65 wt %, lessthan or equal to 60 wt %, less than or equal to 55 wt %, less than orequal to 50 wt %, less than or equal to 45 wt %, less than or equal to40 wt %, less than or equal to 35 wt %, less than or equal to 30 wt %,less than or equal to 25 wt %, less than or equal to 20 wt %, less thanor equal to 15 wt %, less than or equal to 10 wt %, or less than orequal to 5 wt % versus the total weight of carbon present in thecapacitance layer. Combinations of the above referenced ranges are alsopossible (e.g., greater than or equal to 1 wt % and less than or equalto 95 wt %, greater than or equal to 50 wt % and less than or equal to95 wt %, greater than or equal to 80 wt % and less than or equal to 90wt %). Other ranges are also possible.

In embodiments in which the capacitance layer includes activated carbon,the capacitance layer may have a desirable specific capacitance.Specific capacitance of a layer or battery component, as used herein, isthe absolute capacitance value measured in Farad (F) as determined bythe IEC 62576 standard, divided by the mass of activated carbon (g) inthe layer or battery component. In some embodiments, the specificcapacitance of a layer (e.g., a capacitance layer) or battery componentdescribed herein may be greater than or equal to 1 F/g, greater than orequal to 5 F/g, greater than or equal to 10 F/g, greater than or equalto 20 F/g, greater than or equal to 30 F/g, greater than or equal to 40F/g, greater than or equal to 50 F/g, greater than or equal to 60 F/g,greater than or equal to 70 F/g, greater than or equal to 80 F/g, orgreater than or equal to 90 F/g. In some embodiments, the specificcapacitance may be less than or equal to 100 F/g, less than or equal to90 F/g, less than or equal to 80 F/g, less than or equal to 70 F/g, lessthan or equal to 60 F/g, less than or equal to 50 F/g, less than orequal to 40 F/g, less than or equal to 30 F/g, less than or equal to 20F/g, or less than or equal to 10 F/g. Combinations of the abovereferenced ranges are also possible (e.g., greater than or equal to 20F/g and less than or equal to 80 F/g, greater than or equal to 20 F/gand less than or equal to 60 F/g). Other ranges are also possible.

As described herein, in some embodiments, the capacitance layercomprises a binder. Non-limiting examples of suitable binder materialfor the capacitance layer include PTFE, CMC, SBR, acrylic, PVDF, andcombinations thereof. The binder may be useful for, for example, bindingthe conductive carbon and/or the activated carbon to at least a portionof the plurality of fibers in the capacitance layer.

In some embodiments, the binder is present within the capacitance layerin amount of greater than or equal to 1 wt %, greater than or equal to 5wt %, greater than or equal to 10 wt %, greater than or equal to 20 wt%, greater than or equal to 30 wt %, or greater than or equal to 40 wt %versus the total weight of the capacitance layer. in certainembodiments, the binder is present within the capacitance layer in anamount of less than or equal to 50 wt %, less than or equal to 40 wt %,less than or equal to 30 wt %, less than or equal to 20 wt %, less thanor equal to 10 wt %, less than or equal to 5 wt %, or less than or equalto 2 wt % versus the total weight of the capacitance layer. Combinationsof the above referenced ranges are also possible (e.g., greater than orequal to 1 wt % and less than or equal to 50 wt %, greater than or equalto 1 wt % and less than or equal to 30 wt %, greater than or equal to 1wt % and less than or equal to 20 wt %). Other ranges are also possible.

In certain embodiments, the capacitance layer comprises a hydrogensuppressant. Non-limiting examples of hydrogen suppressants suitable foruse in a capacitance layer include oxides, hydroxides, sulfates (e.g.,sulfates of lead, zinc, cadmium, bismuth, and/or silver), tin, titanium,cobalt, antimony, and combinations thereof. The hydrogen suppressantsmay be present in the capacitance layer in any suitable amount. In someembodiments, the hydrogen suppressant is present in the capacitancelayer in an amount of greater than or equal to 0.1 wt %, greater than orequal to 0.2 wt %, greater than or equal to 0.3 wt %, greater than orequal to 0.4 wt %, greater than or equal to 0.5 wt %, greater than orequal to 0.6 wt %, greater than or equal to 0.8 wt %, greater than orequal to 1 wt %, greater than or equal to 1.2 wt %, greater than orequal to 1.5 wt %, greater than or equal to 2 wt %, greater than orequal to 3 wt %, greater than or equal to 4 wt %, greater than or equalto 5 wt %, greater than or equal to 6 wt %, greater than or equal to 7wt %, greater than or equal to 8 wt %, or greater than or equal to 9 wt% versus the total weight of the capacitance layer. In certainembodiments, the hydrogen suppressant is present in the capacitancelayer in an amount less than or equal to 10 wt %, less than or equal to9 wt %, less than or equal to 8 wt %, less than or equal to 7 wt %, lessthan or equal to 6 wt %, less than or equal to 5 wt %, less than orequal to 4 wt %, less than or equal to 3 wt %, less than or equal to 2wt %, less than or equal to 1.5 wt %, less than or equal to 1.2 wt %,less than or equal to 1 wt %, less than or equal to 0.8 wt %, less thanor equal to 0.6 wt %, less than or equal to 0.5 wt %, less than or equalto 0.4 wt %, less than or equal to 0.3 wt %, or less than or equal to0.2 wt % versus the total weight of the capacitance layer. Combinationsof the above-referenced ranges are possible (e.g., greater than or equalto 0.1 wt % and less than or equal to 10 wt %, greater than or equal to0.1 wt % and less than or equal to 5 wt %, greater than or equal to 0.1wt % and less than or equal to 2 wt %). Other ranges are also possible.

The capacitance layers described herein may have desirable propertiesincluding a particular electrical resistivity and/or a particularelectrical conductivity. In some embodiments, the electrical resistivityof the capacitance layer may be greater than or equal to 0.001 ohm,greater than or equal to 0.005 ohm, greater than or equal to 0.01 ohm,greater than or equal to 0.05 ohm, greater than or equal to 0.1 ohm,greater than or equal to 0.5 ohm, greater than equal to 1 ohm, greaterthan or equal to 2 ohm, greater than or equal to 3 ohm, greater than orequal to 4 ohm, greater than or equal to 5 ohm, greater than equal to 6ohm, greater than or equal to 7 ohm, greater than or equal to 8 ohm, orgreater than or equal to 9 ohm. In certain embodiments, the electricalresistivity of the capacitance layer is less than or equal to 10 ohm,less than or equal to 9 ohm, less than or equal to 8 ohm, less than orequal to 7 ohm, less than or equal to 6 ohm., less than or equal to 5ohm, less than or equal to 4 ohm, less than or equal to 3 ohm, less thanor equal to 2 ohm, less than or equal to 1 ohm, less than or equal to0.5 ohm, less than or equal to 0.1 ohm, or less than or equal to 0.005ohm. Combinations of the above-referenced ranges are also possible (e.g.greater than or equal to 0.001 ohm and less than or equal to 10 ohm,greater than or equal to 0.001 ohm and less than or equal to 2 ohm),Other ranges are also possible. Electrical resistivity may be measuredaccording to testing standard IEC 62576 Ed. 1.0 b:2009.

In certain embodiments, the electrical conductivity of the capacitancelayer may be greater than or equal to 0.1 S/m, greater than or equal to0.2 S/m, greater than or equal to 0.5 S/m, greater than or equal to 1S/m, greater than or equal to 2 S/m, greater than or equal to 5 S/m.,greater than or equal to 10 S/m, greater than or equal to 25 S/m,greater than or equal to 50 S/m, greater than or equal to 75 S/m,greater than or equal to 100 S/m, greater than or equal to 150 S/m,greater than or equal to 200 S/m, greater than or equal to 250 S/m,greater than or equal to 500 S/m, greater than or equal to 600 S/m,greater than or equal to 750 S/m, greater than or equal to 800 S/m, orgreater than or equal to 900 S/m. In certain embodiments, the electricalconductivity of the capacitance layer is less than or equal to 1000 S/m,less than or equal to 900 S/m, less than or equal to 800 S/m, less thanor equal to 750 S/m, less than or equal to 600 S/m., less than or equalto 500 S/m, less than or equal to 250 S/m, less than or equal to 150S/m, less than or equal to 100 S/m, less than or equal to 75 S/m, lessthan or equal to 50 S/m, less than or equal to 25 S/m, less than orequal to 10 S/m, less than or equal to 5 S/m, less than or equal to 2S/m, less than or equal to 1 S/m, less than or equal to 0.5 S/m, or lessthan or equal to 0.2 S/m. Combinations of the above-referenced rangesare possible (e.g., greater than or equal to 0.1 S/m and less than orequal to 1000 S/m, greater than or equal to 0.2 S/m and less than orequal to 1000 S/m). Other ranges are also possible. Electricalconductivity may be determined from the electrical resistivity asmeasured according to testing standard IS 6071-1986 IEC 62576.

In an exemplary embodiment, the capacitance layer comprises a pluralityof fibers (e.g., a plurality of glass fibers), conductive carbon, andactivated carbon. In some embodiments, the capacitance layer may be astand-alone layer in a battery. For example, in some cases, thecapacitance layer may be formed separately from the remaining componentsof the battery and then positioned adjacent one or more of thecomponents in the battery. In some embodiments, the ratio of activatedcarbon to conductive carbon in the capacitance layer is greater than orequal to 90:10 and less than or equal to 94:6. In some embodiments, thetotal carbon (e.g., comprising activated carbon and conductive carbon)is present in the capacitance layer in an amount of greater than orequal to 80 wt % and less than or equal to 90 wt % (e.g., greater thanor equal to 84 wt %) versus the total weight of the capacitance layer.In some embodiments, the plurality of fibers (e.g., the plurality ofglass fibers) are present within the capacitance layer in an amount ofgreater than 0 wt % and less than or equal to 95 wt % (or anothersuitable range described herein) versus the total weight of thecapacitance layer. In some embodiments, capacitance layer includes bothfine glass fibers (e.g., microglass fibers) and coarse glass fibers(e.g., chopped strand fibers). The ratio of fine glass fibers (e.g.,microglass fibers) to coarse glass fibers (e.g., chopped strand fibers)in the capacitance layer may be, for example, greater than or equal to10:90 and less than or equal to 90:10 (or another suitable rangedescribed herein). In some embodiments, a binder may be present in thecapacitance layer in an amount less than or equal to 5 wt % and greaterthan or equal to 1 wt % (e.g., less than or equal to 2 wt %) versus thetotal weight of the capacitance layer. In some embodiments, a hydrogensuppressant is present in the capacitance layer in an amount of greaterthan or equal to 0.1 wt % and less than or equal to 10 wt % versus thetotal weight of the capacitance layer. Other configurations and rangesare also possible.

As noted above, a battery component described herein (or fiber layer ofthe battery component) may be used in a battery such as a lead acidbattery. The battery may comprise a negative plate, a positive plate,and a battery component (e.g., including a fiber layer describedherein). In some embodiments, the battery component can be disposedbetween the negative and positive plates. In some embodiments, thebattery component can be combined with a battery grid to form a part ofthe plate. In some embodiments, the battery grid may be punched orexpanded. In an exemplary embodiment, the battery grid is a lead grid(e.g., a lead alloy grid).

The battery component may be applied to the negative plate and/or thepositive plate. Once applied, the battery component (e.g., the pastingpaper) is integrated into the battery plate and becomes part of theelectrode.

It is to be understood that the other components of the battery that arenot explicitly discussed herein can be conventional battery components.Positive plates and negative plates can be formed of conventional leadacid battery plate materials. For example, in container formattedbatteries, plates can include grids that include a conductive material,which can include, but is not limited to, lead, lead alloys, graphite,carbon, carbon foam, titanium, ceramics (such as Ebonex®), laminates andcomposite materials. The grids are typically pasted with activematerials. The pasted grids are typically converted to positive andnegative battery plates by a process called “formation.” Formationinvolves passing an electric current through an assembly of alternatingpositive and negative plates with separators between adjacent plateswhile the assembly is in a suitable electrolyte (e.g., to convert pastedoxide to active materials).

As a specific example, positive plates may contain lead dioxide as theactive material, and negative plates may contain lead as the activematerial. Plates can also contain one or more reinforcing materials,such as chopped organic fibers (e.g., having lu an average length of0.125 inch or more), chopped glass fibers, metal sulfate(s) (e.g.,nickel sulfate, copper sulfate), red lead (e.g., a Pb₃O₄-containingmaterial), litharge, paraffin oil, and/or expander(s). In someembodiments, an expander contains barium sulfate, carbon black andlignin sulfonate as the primary components. The components of theexpander(s) can be pre-mixed or not pre-mixed. Expanders arecommercially available from, for example, Hammond Lead Products(Hammond, Ind.) and Atomized Products Group, Inc. (Garland, Tex.).

An example of a commercially available expander is the Texex® expander(Atomized Products Group, Inc.). In certain embodiments, theexpander(s), metal sulfate(s) and/or paraffin are present in positiveplates, but not negative plates. In some embodiments, positive platesand/or negative plates contain fibrous material or other glasscompositions.

A battery can be assembled using any desired technique. For example, abattery component may be cut into a sheet and may be placed between twoplates, or the component may be wrapped around the plates (e.g.,positive electrode, negative electrode). The positive plates, negativeplates and component are then assembled in a case using conventionallead acid battery assembly methods. The battery component may be used,in some embodiments, as a pasting paper and/or a conductive layer orcapacitance layer. In some embodiments, the battery component isadjacent (e.g., directly adjacent) an electrode of the battery (e.g.,the positive electrode, the negative electrode). For example, in one setof embodiments, the battery component is applied as a pasting paper tothe battery plate and is integrated into the plate, making it a part ofthe electrode. In certain embodiments, the components are compressedafter they are assembled in the case, i.e., the thickness of thecomponents are reduced after they are placed into the case. Anelectrolyte (e.g., sulfuric acid) is then disposed in the case. Itshould be understood that the shapes (e.g., planar) of the batterycomponents described herein are non-limiting and the battery componentsdescribed herein may have any suitable shape.

In some embodiments, a battery component described herein may be used,for example, in combination with (e.g., positioned adjacent) a leafseparator, an envelope separator (i.e., the separator is sealed on threesides), a z-fold separator, a sleeve separator, a corrugated separator,C-wrap separator, or a U-wrap separator. In certain embodiments, theseparator is a non-woven glass separator.

In some embodiments, the battery components (e.g., including the fiberlayers described herein) may be used in lead acid batteries includingvalve-regulated batteries (e.g., absorbent glass mat batteries). In avalve-regulated lead acid (VRLA) battery, for example, the internalenvironment is controlled by a valve for venting, the valve vents gas(e.g., hydrogen, oxygen) from the battery as pressure builds. The valveis a pressure relief valve, only opening when the internal batterypressure reaches a threshold. When the internal pressure in the batteryis below this threshold the valve prevents either gas from escaping.Generated O₂ can diffuse from the positive electrode to the negativeelectrode. Discharging the negative electrode generally enablesrecombination of the oxygen ions in the electrolyte, which acts tosuppress hydrogen generation. The ability of a valve regulated lead acidbattery (VRLA) to recombine oxygen governs several facets of the batteryperformance and safety. Hydrogen is an explosive gas, and thusrecombination of oxygen is important to reduce the potential of anexplosion. A low level of recombination of oxygen also negativelyaffects the charge acceptance of the battery. The battery separatorsdescribed herein may facilitate the recombination of oxygen, reduceshydrogen formation, and thus increase the efficiency and performance ofthe battery.

Fiber layers described herein may be produced using suitable processes,such as a wet laid process. In general, a wet laid process involvesmixing together fibers of one or more type; for example, glass fibers ofone type may be mixed together with glass fibers of another type, and/orwith fibers of a different type (e.g., fibrillated fibers), to provide afiber slurry. The slurry may be, for example, an aqueous-based slurry.In certain embodiments, fibers, are optionally stored separately, or incombination, in various holding tanks prior to being mixed together.

For instance, a first fiber may be mixed and pulped together in onecontainer and a second fiber may be mixed and pulped in a separatecontainer. The first fibers and the second fibers may subsequently becombined together into a single fibrous mixture. Appropriate fibers maybe processed through a pulper before and/or after being mixed together.In some embodiments, combinations of fibers are processed through apulper and/or a holding tank prior to being mixed together. It can beappreciated that other components (e.g., inorganic particles) may alsobe introduced into the mixture. Furthermore, it should be appreciatedthat other combinations of fibers types may be used in fiber mixtures,such as the fiber types described herein.

Any suitable method for creating a fiber slurry may be used. In someembodiments, further additives are added to the slurry to facilitateprocessing. The temperature may also be adjusted to a suitable range,for example, between 33° F. and 100° F. (e.g., between 50° F. and 85°F.). In some cases, the temperature of the slurry is maintained. In someinstances, the temperature is not actively adjusted.

In some embodiments, the wet laid process uses similar equipment as in aconventional papermaking process, for example, a hydropulper, a formeror a headbox, a dryer, and an optional converter. As discussed above,the slurry may be prepared in one or more pulpers. After appropriatelymixing the slurry in a pulper, the slurry may be pumped into a headboxwhere the slurry may or may not be combined with other slurries. Otheradditives may or may not be added. The slurry may also be diluted withadditional water such that the final concentration of fiber is in asuitable ranae, such as for example, between about 0.1% and 0.5% byweight.

In some embodiments in which additives (e.g., carbon-based additivessuch as conductive carbon and activated carbon) are included in thefiber web such as for formation of a pasting paper battery component,the additives may be added to the fiber slurry in any suitable amount.Additional components (e.g., one or more retention aids) may also beadded to the slurry. The additives and/or additional components may beadded to the fiber slurry at any stage before the fiber slurry entersthe headbox. In other embodiments, such as for a capacitance paperbatter component, additives (e.g., carbon-based additives such asconductive carbon and activated carbon) may be added after formation ofthe fiber web.

In some cases, the pH of the fiber slurry may be adjusted as desired.For instance, fibers of the slurry may be dispersed under acidic orneutral conditions.

Before the slurry is sent to a headbox, the slurry may optionally bepassed through centrifugal cleaners and/or pressure screens for removingunfiberized material. The slurry may or may not be passed throughadditional equipment such as refiners or deflakers to further enhancethe dispersion of the fibers. For example, deflakers may be useful tosmooth out or remove lumps or protrusions that may arise at any pointduring formation of the fiber slurry. Fibers may then be collected on toa screen or wire at an appropriate rate using any suitable equipment,e.g., a fourdrinier, a rotoformer, a cylinder/round former, or aninclined wire fourdrinier.

In some embodiments two or more layers of a battery component may beformed separately, and combined by any suitable method such aslamination, collation, or by use of adhesives. The two or more layersmay be formed using different processes, or the same process. Forexample, each of the layers may be independently formed by a wet laidprocess, a non-wet laid process, or any other suitable process.

In some embodiments, two or more layers may be formed by the sameprocess. In some instances, the two or more layers may be formedsimultaneously.

Different layers may be adhered together by any suitable method. Forinstance, layers may be adhered by an adhesive and/or melt-bonded to oneanother on either side. Lamination and calendering processes may also beused. In some embodiments, an additional layer may be formed from anytype of fiber or blend of fibers via an added headbox or a coater andappropriately adhered to another layer.

In some embodiments, the battery component may be formed at least inpart by coating a pre-formed fiber layer (e.g., comprising a pluralityof fibers, such as a fiber web described herein) with a slurry (e.g.,comprising activated and conductive carbon) and/or a paste on at least aportion of the fiber layer.

Any suitable coating method may be used to form a coating on the fiberlayer. In some embodiments, the coating or slurry may be applied to thefiber layer using a non-compressive coating technique. Thenon-compressive coating technique may coat the fiber layer, while notsubstantially decreasing the thickness of the layer. In otherembodiments, the coating or slurry may be applied to the fiber layerusing a compressive coating technique. Non-limiting examples of coatingmethods include the use of a slot die coater, gravure coating, sizepress coating (e.g., a two roll-type or a metering blade type size presscoater), film press coating, blade coating, roll-blade coating, airknife coating, roll coating, foam application, reverse roll coating, barcoating, curtain coating, champlex coating, brush coating, Bill-bladecoating, short dwell-blade coating, lip coating, gate roll coating, gateroll size press coating, lab coating, melt coating, dip coating, kniferoll coating, spin coating, spray coating, and saturation impregnation.Other coating methods are also possible.

The coating or slurry may coat any suitable portion of the fiber layer.In some embodiments, the coating or slurry may be formed such that thesurfaces of the fiber layer are coated without substantially coating theinterior of the fiber layer. In some instances, a single surface of thefiber layer may be coated. For example, a top surface of the fiber layermay be coated. In other instances, more than one surface of the fiberlayer may be coated (e.g., the top and bottom surfaces). In otherembodiments, at least a portion of the interior of the fiber layer maybe coated without substantially coating at least one surface of fiberlayer. The coating or slurry may also be formed such that at least onesurface of the fiber layer and the interior of the fiber layer arecoated. In some embodiments, the entire fiber layer is coated. Forexample, the fibers of the fiber web may be impregnated with the coatingor slurry in some embodiments.

In an exemplary embodiment, a battery component (e.g., such as a pastingpaper) for use in an electrochemical cell has a total wt % of carbon(e.g., comprising activated carbon and conductive carbon) greater thanor equal to 50 wt % and less than or equal to 90 wt % (e.g., greaterthan or equal to 80 wt % and less than or equal to 90 wt %) versus thetotal weight of the battery component. In an exemplary configuration,the total wt % of carbon present in the battery component may be 90 wt %versus the total weight of the battery component. In some cases, thebattery component may comprise a plurality of fine glass fibers in anamount greater than or equal to 3 wt % and less than or equal to 6 wt %versus the total battery component weight, a plurality of coarse glassfibers in an amount greater than or equal to 3 wt % and less than orequal to 6 wt % versus the total battery component weight, a pluralityof fibrillated fibers in an amount greater than or equal to 0.1 wt % andless than or equal to 1.5 wt % versus the total battery componentweight, a plurality of bicomponent fibers in an amount greater than orequal to 0 wt % and less than or equal to 1 wt % versus the totalbattery component weight, a resin in an amount greater than or equal to0.1 wt % and less than or equal to 1.5 wt % versus the total batterycomponent weight, and a binder in an amount greater than or equal to 1wt % and less than or equal to 2 wt % versus the total battery componentweight.

EXAMPLES

The following examples are intended to illustrate certain embodiments ofthe present invention, but are not to be construed as limiting and donot exemplify the full scope of the invention.

Example 1

The following example demonstrates the formation of a pasting paperbattery component for use in an electrochemical cell, according to someembodiments.

The pasting paper battery component (Sample 1), included:

A plurality of fine glass fibers (1.5 micron avg. diameter): 41 wt %

A plurality of coarse glass fibers (2.6 micron avg. diameter): 41 wt %

A plurality of coarse glass fibers (13.5 micron avg. diameter): 7 wt %

A plurality of bicomponent (PET core/PE sheath) fibers 1.3 dtex, 6 mmlong: 2 wt %

A plurality of fibrillated Cellulosic (cedar pulp) fibers (40 micronavg. fiber diameter): 7 wt %; and

Resin: 2 wt %.

FIG. 3 shows a plot of the normalized performance characteristics(specific surface area (“SSA”), pore size (“pore size”), and dry tensilestrength (“tensile”)) of the battery component described above(Sample 1) as compared to two comparative battery components (Sample 2and Sample 3). The first comparative battery component (Sample 2)included:

A plurality of coarse glass fibers (8 micron avg. diameter): 47.5 wt %

A plurality of coarse glass fibers (chopped, 13.5 micron avg. diameter):12 wt %

A plurality of coarse glass fibers (3 micron avg. diameter): 23.5 wt %

A plurality of fibrillated cellulosic fibers: 17 wt %

The second comparative battery component (Sample 3) included:

A plurality of fine glass fibers (0.8 micron avg. diameter): 80 wt %

A plurality of coarse glass fibers (3 micron avg. diameter): 20 wt %

The normalized value was obtained by dividing the measured value of theproperty for each battery component by the maximum value for thatproperty for all samples (e.g., the pore size for each battery componentwas divided by the maximum pore size of all battery components). Thepasting paper battery component (Sample 1) demonstrates a desirablebalance between specific surface area, dry tensile strength, and meanpore size (e.g., generally resulting in a desirable balance betweenresistance to acid stratification, ease of processability, and pasteadhesion). By contrast, Sample 2 had a relatively high mean pore sizeand relatively high dry tensile strength, with relatively low specificsurface area compared to Sample 1. Similarly, Sample 3 had relativelyhigh specific surface area, with relatively low mean pore size andrelatively low dry tensile strength compared to Sample 1.

Example 2

The following example demonstrates the formation of a capacitance layerfor use in an electrochemical cell, according to some embodiments.

Capacitance layers with varying formulations (varying amount ofactivated carbon (AC) to conductive carbon (CC) ratio) were formed andtested.

Sample 1 included a ratio of 100:0 AC:CC.

Sample 2 included a ratio of 0:100 AC:CC.

Sample 3 included a ratio of 50:50 AC:CC.

Sample 4 included a ratio of 89.6:10.4 AC:CC.

Sample 5 included a ratio of 93.75:6.25 AC:CC.

PTFE binder with water/isopropanol as a solvent/dispersant was used forall samples. Each capacitance layer was laminated to a fiber layercomprising a plurality of glass fibers such that the AC/CC/binder wasembedded into the fiber layer. Water/isopropanol was evaporated whiledrying the capacitance layer. In this form the glass scrim was about 10%(wt %) of the total weight of the capacitance layer. The binder waspresent in an amount of about 3-4 wt % versus the total weight of thecapacitance layer. The weight percentage of AC and CC in each samplewas:

Sample 1: 86 wt % AC; 0 wt % CC.

Sample 2: 0 wt % AC; 86 wt % CC.

Sample 3: 43 wt % AC; 43 wt % CC.

Sample 4: 77.5 wt % AC; 9 wt % CC.

Sample 5: 81 wt % AC; 5.5 wt % CC.

Symmetric capacitors were made for these five samples and theirperformance evaluation using specific capacitance and Equivalent SeriesResistance (ESR) values were measured. Samples 4 and 5 demonstrated thebest performing formulations with high specific capacitance and low ESR.Specific capacitance values in excess of 40 F/g and ESR values as low as0.13 Ohms were obtained for Samples 4 and 5. Specific capacitance andESR for Samples 1-3 were not determined due to poor electricalcharacteristics. For example, Sample 1 having 86 wt % AC had poorstructural interconnections and poor electrical behavior (e.g., thedevice was unable to be fully charged). Similarly, Samples 2 and 3 wereunable to be charged and had no significant specific capacitance.

What is claimed is:
 1. A battery component, comprising: a plurality offine glass fibers having an average fiber diameter of less than 2microns, wherein the plurality of fine glass fibers are present in anamount greater than or equal to 30 wt % and less than or equal to 60 wt% versus the total weight of the battery component; a plurality ofcoarse glass fibers having an average fiber diameter of greater than orequal to 2 microns, wherein the plurality of coarse glass fibers arepresent in an amount greater than or equal to 30 wt % and less than orequal to 60 wt % versus the total weight of the battery component; aplurality of fibrillated fibers present in an amount greater than orequal to 1 wt % and less than or equal to 15 wt % versus the totalweight of the battery component; a resin present in an amount greaterthan or equal to 1 wt % and less than or equal to 10 wt % versus thetotal weight of the battery component; and a plurality of bicomponentfibers present in an amount of greater than 0 wt % and less than orequal to 8 wt % versus the total weight of the battery component,wherein the battery component has a Cobb parameter of greater than orequal to 50 gsm.
 2. A battery component as in claim 1, wherein theplurality of fine glass fibers have an average fiber diameter of lessthan or equal to 1 micron, wherein the plurality of coarse glass fibershave an average fiber diameter of greater than 5 microns, wherein thebattery component has a basis weight of greater than or equal to 10 g/m²and less than or equal to 200 g/m², wherein the battery component has aspecific surface area of greater than or equal to 0.2 m²/g and less thanor equal to 5 m²/g, and wherein the battery component has a mean poresize of greater than or equal to 0.1 microns and less than or equal to15 microns.
 3. A battery component, comprising: a plurality of fineglass fibers having an average fiber diameter of less than 2 microns,wherein the plurality of fine glass fibers are present in an amountgreater than or equal to 30 wt % and less than or equal to 60 wt %versus the total weight of the battery component; a plurality of coarseglass fibers having an average fiber diameter of greater than or equalto 2 microns, wherein the plurality of coarse glass fibers are presentin an amount greater than or equal to 30 wt % and less than or equal to60 wt % versus the total weight of the battery component; a plurality offibrillated fibers present in an amount greater than or equal to 1 wt %and less than or equal to 15 wt % versus the total weight of the batterycomponent; and a resin present in an amount greater than or equal to 1wt % and less than or equal to 10 wt % versus the total weight of thebattery component, wherein the battery component has an air permeabilityof greater than or equal to 1 CFM and less than or equal to 1000 CFM,and wherein the battery component has a Cobb parameter of greater thanor equal to 50 gsm.
 4. A battery plate, comprising: a lead grid; and abattery component as in claim
 3. 5. A battery component as in claim 3,wherein the battery component comprises activated carbon and conductivecarbon, and wherein the ratio of activated carbon to conductive carbonis greater than or equal to 90:10 and less than or equal to 94:6.
 6. Abattery component as in claim 3, wherein the battery component comprisesa hydrogen suppressant in an amount of less than or equal to 2 wt %versus the total weight of the battery component.
 7. A battery componentas in claim 3, wherein the plurality of fine glass fibers have anaverage fiber diameter of less than or equal to 1 micron.
 8. A batterycomponent as in claim 3, wherein the plurality of coarse glass fibershave an average fiber diameter of greater than 5 microns.
 9. A batterycomponent as in claim 3, wherein the plurality of fibrillated fibershave a Canadian Standard Freeness (CSF) of greater than or equal to 20CSF and less than or equal to 650 CSF.
 10. A battery component as inclaim 3, wherein the plurality of fibrillated fibers comprisecellulose-based fibers, acrylics, liquid crystalline polymers,polyoxazoles, aramids, p-aramids, polyethylenes, polyesters, polyamides,cotton, polyolefins, and/or olefins.
 11. A battery component as in claim3, wherein the resin is a hydrophobic resin.
 12. A battery component asin claim 3, wherein the battery component has a basis weight of greaterthan or equal to 10 g/m² and less than or equal to 200 g/m².
 13. Abattery component as in claim 3, wherein the battery component has aspecific surface area of greater than or equal to 0.2 m²/g and less thanor equal to 5 m²/g.
 14. A battery component as in claim 3, wherein thebattery component has a mean pore size of greater than or equal to 0.1microns and less than or equal to 15 microns.
 15. A battery component asin claim 3, wherein the battery component has a dry tensile strength ofgreater than or equal to 0.1 pounds per inch and less than or equal to15 pounds per inch.
 16. A lead acid battery comprising, a negativeplate; a positive plate; and a battery component as in claim 3 disposedbetween the negative and positive plates.
 17. A battery component as inclaim 3, wherein the plurality of fine glass fibers have an averagefiber diameter of less than or equal to 1 micron, wherein the pluralityof coarse glass fibers have an average fiber diameter of greater than 5microns, wherein the battery component has a basis weight of greaterthan or equal to 10 g/m² and less than or equal to 200 g/m², wherein thebattery component has a specific surface area of greater than or equalto 0.2 m²/g and less than or equal to 5 m²/g, and wherein the batterycomponent has a mean pore size of greater than or equal to 0.1 micronsand less than or equal to 15 microns.
 18. A battery component,comprising: a plurality of fine glass fibers having an average fiberdiameter of less than 2 microns, wherein the plurality of fine glassfibers are present in an amount greater than or equal to 30 wt % andless than or equal to 60 wt % versus the total weight of the batterycomponent; a plurality of coarse glass fibers having an average fiberdiameter of greater than or equal to 2 microns, wherein the plurality ofcoarse glass fibers are present in an amount greater than or equal to 30wt % and less than or equal to 60 wt % versus the total weight of thebattery component; a plurality of fibrillated fibers present in anamount greater than or equal to 1 wt % and less than or equal to 15 wt %versus the total weight of the battery component; and a resin present inan amount greater than or equal to 1 wt % and less than or equal to 10wt % versus the total weight of the battery component, wherein the resinis hydrophobic, and wherein the battery component has a Cobb parameterof greater than or equal to 50 gsm.
 19. A battery component as in claim18, wherein the plurality of fine glass fibers have an average fiberdiameter of less than or equal to 1 micron, wherein the plurality ofcoarse glass fibers have an average fiber diameter of greater than 5microns, wherein the battery component has a basis weight of greaterthan or equal to 10 g/m² and less than or equal to 200 g/m², wherein thebattery component has a specific surface area of greater than or equalto 0.2 m²/g and less than or equal to 5 m²/g, and wherein the batterycomponent has a mean pore size of greater than or equal to 0.1 micronsand less than or equal to 15 microns.
 20. A battery component,comprising: a plurality of fine glass fibers having an average fiberdiameter of less than 2 microns; a plurality of coarse glass fibershaving an average fiber diameter of greater than or equal to 2 microns;and a plurality of fibrillated fibers, wherein the battery component hasa surface area of greater than or equal to 0.5 m²/g and less than orequal to 100 m²/g, wherein the battery component has a mean pore size ofgreater than or equal to 0.1 microns and less than or equal to 15microns, wherein the battery component has a dry tensile strength in themachine direction of greater than or equal to 0.1 lbs. per inch and lessthan or equal to 15 lbs. per inch, and wherein the battery component hasa Cobb parameter of greater than or equal to 50 gsm.
 21. A batterycomponent as in claim 20, wherein the plurality of fine glass fibershave an average fiber diameter of less than or equal to 1 micron,wherein the plurality of coarse glass fibers have an average fiberdiameter of greater than 5 microns, wherein the battery component has abasis weight of greater than or equal to 10 g/m² and less than or equalto 200 g/m², wherein the battery component has a specific surface areaof greater than or equal to 0.2 m²/g and less than or equal to 5 m²/g,and wherein the battery component has a mean pore size of greater thanor equal to 0.1 microns and less than or equal to 15 microns.
 22. Abattery component, comprising: a plurality of fine glass fibers havingan average fiber diameter of less than 2 microns, wherein the pluralityof fine glass fibers are present in an amount greater than or equal to30 wt % and less than or equal to 60 wt % versus the total weight of thebattery component; a plurality of coarse glass fibers having an averagefiber diameter of greater than or equal to 2 microns, wherein theplurality of coarse glass fibers are present in an amount greater thanor equal to 30 wt % and less than or equal to 60 wt % versus the totalweight of the battery component; a plurality of fibrillated fiberspresent in an amount greater than or equal to 1 wt % and less than orequal to 15 wt % versus the total weight of the battery component; aresin present in an amount greater than or equal to 1 wt % and less thanor equal to 10 wt % versus the total weight of the battery component;and a plurality of bicomponent fibers present in an amount of greaterthan 0 wt % and less than or equal to 8 wt % versus the total weight ofthe battery component, wherein the battery component comprises ahydrogen suppressant in an amount of less than or equal to 2 wt % versusthe total weight of the battery component.
 23. A battery component,comprising: a plurality of fine glass fibers having an average fiberdiameter of less than 2 microns, wherein the plurality of fine glassfibers are present in an amount greater than or equal to 30 wt % andless than or equal to 60 wt % versus the total weight of the batterycomponent; a plurality of coarse glass fibers having an average fiberdiameter of greater than or equal to 2 microns, wherein the plurality ofcoarse glass fibers are present in an amount greater than or equal to 30wt % and less than or equal to 60 wt % versus the total weight of thebattery component; a plurality of fibrillated fibers present in anamount greater than or equal to 1 wt % and less than or equal to 15 wt %versus the total weight of the battery component; a resin present in anamount greater than or equal to 1 wt % and less than or equal to 10 wt %versus the total weight of the battery component; and a plurality ofbicomponent fibers present in an amount of greater than 0 wt % and lessthan or equal to 8 wt % versus the total weight of the batterycomponent, wherein the battery component comprises activated carbon andconductive carbon, and wherein the ratio of activated carbon toconductive carbon is greater than or equal to 90:10 and less than orequal to 94:6.